Failure to heed the warnings and safety precautions
contained in this manual can result in severe injury or death.
Read this manual carefully.
Owner's Manual
for Maintenance and Safety
SPORTSMAN ACE
™
WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
• RZR® sport vehicles
• VICTORY® motorcycles
• GEM® electric vehicles
We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design and development of
your POLARIS vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Review the
safety DVD that came with your vehicle. POLARIS also recommends
that all drivers take the ROHVA safety e-course and a ROHVA hands-on
safety training course. Visit www.rohva.org or call 866-267-2751.
Your manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the POLARIS Service Manual
and should be performed only by a factory certified Master Service
Dealer® (MSD) Technician.
Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
2
POLARIS® and SPORTSMAN ACE™ are trademarks of POLARIS Industries Inc.
Copyright 2013 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in
this publication. Depictions and/or procedures in this publication are intended for
reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole
or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2014 SPORTSMAN ACE Owner’s Manual
P/N 9924083
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Emission Control Systems . . . . . . . . . . . . . . . 78
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 128
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 130
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 131
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 142
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4
INTRODUCTION
This POLARIS vehicle is an off-road vehicle. Familiarize yourself with
all laws and regulations concerning the operation of this vehicle in your
area.
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and
symbols are used. Become familiar with their meanings before reading
the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
5
INTRODUCTION
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your local
POLARIS dealer. Understand all safety warnings, precautions and operating
procedures before operating the vehicle. Keep this manual with the vehicle.
• Never operate this vehicle without proper instruction. Take an authorized
training course. Visit www.rohva.org or call 866-267-2751.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and
have a valid driver’s license to operate this vehicle.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the New Operator Driving Procedures outlined on pages 54-55.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.
• Never permit a guest to operate this vehicle unless the guest has reviewed the
owner’s manual and all safety labels and has completed a safety training
course.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as
indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many
factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING
6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Vehicle Identification Number (VIN): _________________________________________
Engine Serial Number: ___________________________________________________
Key Number____________________________________________________________
Engine Serial
Number
Key
Number
VIN
(Right Front Frame)
####
7
SAFETY
Safety Training
Safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding this vehicle
to take a training course.
ROHVA (Recreational Off-Highway Vehicle Association) provides both
an online safety e-course and a hands-on safety course. Visit
www.rohva.org or call 866-267-2751.
Your POLARIS vehicle is considered an off-road vehicle. Familiarize
yourself with all laws and regulations concerning the operation of this
vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your
vehicle are thoroughly inspected at specific intervals.
For more information about recreational off-road vehicle safety in
the United States, visit www.rohva.org, call 866-267-2751 or call
POLARIS at 800-342-3764.
8
SAFETY
Safe Riding Gear
Always wear helmet, eye protection, gloves, long-sleeve shirt, long
pants, over-the-ankle boots and seat belt at all times. Protective gear
reduces the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye
Protection
Gloves
Over-the-Ankle
Boots
Long
Pants
Long
Sleeves
E
4
051039
0006.31
9
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this POLARIS vehicle, always wear shatterproof
goggles or use a shatterproof helmet face shield. POLARIS
recommends wearing approved Personal Protective Equipment (PPE)
bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure
protective eye wear is kept clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and
other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never ride
a POLARIS vehicle with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the rider cab area. The
condition occurs most frequently when a vehicle is being operated in
high ambient temperatures at low speeds and/or high load conditions for
an extended period of time. The use of certain windshield, roof and/or
cab systems may contribute to this condition by restricting airflow. Any
discomfort due to heat buildup in this area can be minimized by wearing
proper riding apparel and by varying speeds to increase airflow.
10
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.
If an informational or graphic label becomes illegible or comes off,
contact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
General Warning
11
SAFETY
Safety Labels and Locations
General Warning
WARNING
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid
driver’s license.
• Do not let people drive after using alcohol or drugs.
• Do not allow operation on public roads (unless
designated for off-highway vehicle access) - collisions with cars and trucks can
occur.
• Do not exceed seating capacity: 1 occupant.
Improper vehicle use can result in SEVERE INJURY or DEATH
Be Prepared
• Fasten seat belt.
• Wear an approved helmet and protective gear.
• ALWAYS use vehicle cab nets and/or doors.
• Driver must be able to sit with back against seat, feet flat on
the floor, and hands on steering wheel. Stay completely
inside the vehicle.
Drive Responsibly
Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways sliding,
skidding or fishtailing, and never do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when turning, even
from a stop.
• Plan for hills, rough terrain, ruts and other
changes in traction and terrain.
• Avoid paved surfaces.
• Avoid sidehilling (riding across slopes).
Be Sure to Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
• Keep a firm grip on the steering wheel and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA
TRAINING (rohva.org).
7180534
Rollovers have caused
severe injuries and death,
even on flat, open areas.
12
SAFETY
Safety Labels and Locations
Load/Passenger/Tire Pressure Warning
WARNING
• Never carry passengers in cargo box.
• Passengers can be thrown off. This can
cause serious injury or death.
WARNING
IMPROPER TIRE PRESSURE OR
OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS
INJURY OR DEATH.
• Reduce speed and allow greater distance
for braking when carrying cargo.
• Overloading or carrying tall, off-center, or
unsecured loads will increase your risk of
losing control. Loads should be centered
and carried as low as possible in box.
• For stability on rough or hilly terrain,
reduce speed and cargo.
7180636
SPORTSMAN ACE
MAXIMUM CARGO BOX LOAD 240 lbs.
(108 kg)
TIRE PRESSURE IN PSI (KPa) FRONT 7 (48)
REAR 7 (48)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF OPERATOR, CARGO AND
ACCESSORIES
575 lbs.
(260 kg)
Read Operation and Maintenance Manual for more detailed loading information.
Load/Passenger/Tire
Pressure Warning
13
SAFETY
Safety Labels and Locations
PVT System Warning
WARNING
Improper service or maintenance of
this PVT system can result in vehicle
damage, SEVERE INJURY or
DEATH.
Always look for and remove debris
inside and around clutch and vent
system when replacing belt.
Read owner's manual or see
authorized Polaris dealer.
7177469
Hitch Capacity Label
TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15 DEGREES
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
7170509
PVT System Warning
14
SAFETY
Safety Warnings
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. See the OPERATION section of the owner’s manual
for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain. Complete the New Operator
Driving Procedures outlined on pages 54-55.
All operators must read and understand the
owner's manual and all warning and instruction
labels before operating the vehicle. Never allow a
guest to operate this vehicle until the guest has
completed the New Operator Driving Procedures
outlined on pages 54-55.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age or anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and
both hands on the steering wheel.
Using Alcohol or Drugs
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
WARNING
15
SAFETY
Safety Warnings
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle
is in safe operating condition before
operating increases the risk of an accident.
Always perform the pre-ride inspection
before each use of your vehicle to make
sure it's in safe operating condition. See
page 48.
Always follow the inspection and
maintenance procedures and schedules
described in this owner’s manual. See
page 79.
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Always wear a helmet, eye protection,
gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of rollover, loss of control, other accident or sudden stop. Seat
belts may reduce the severity of injury in these circumstances.
The operator MUST wear the seat belt at all times.
Cab Nets
Riding in this vehicle without using the cab nets (or doors, if equipped) increases
the risk of serious injury or death in the event of an accident or rollover. Always
use the cab nets (or doors) while riding in this vehicle. Always keep hands and
feet inside the vehicle at all times.
16
SAFETY
Safety Warnings
Carrying a Passenger
This POLARIS vehicle is a single-rider
vehicle. Carrying a passenger greatly
reduces the operator's ability to control
the vehicle, which may result in an
accident or rollover. Carrying a
passenger in the cargo box could result
in a fall from the vehicle or contact with
moving components. Never carry a
passenger on this vehicle.
Operating With a Load on the Vehicle
The weight of both cargo and operator impacts vehicle operation and stability.
For your safety and the safety of others, carefully consider how your vehicle is
loaded and how to safely operate the vehicle. Follow the instructions in this
manual for loading, tire pressure, gear selection and speed.
• Do not exceed vehicle weight capacities. The vehicle’s maximum weight
capacity is listed in the specifications section of this manual and on a label on
the vehicle. When determining the weight you are adding to the vehicle,
include the weight of the operator, accessories, loads in the rack or box and
the load on the trailer tongue. The combined weight of these items must not
exceed the maximum weight capacity.
• The recommended tire pressures are listed in the specifications section of this
manual and on a label on the vehicle.
Always follow these guidelines:
Under ANY of these conditions: Do ALL of these steps:
Operator and/or cargo exceeds half the
maximum weight capacity
1. Slow down.
2. Verify tire pressure.
3. Use extra caution when
operating.
Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing
17
SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this vehicle with improper tires or
with improper or uneven tire pressure could
cause loss of control or accident.
Always use the size and type of tires specified
for your vehicle.
Always maintain proper tire pressure as
described in the owner's manual and on safety
labels.
Operating on Pavement
This vehicle's tires are designed for off-road
use only, not for use on pavement. Operating
this vehicle on paved surfaces (including
sidewalks, paths, parking lots and driveways)
may adversely affect the handling of the
vehicle and may increase the risk of loss of
control and accident or rollover. Avoid
operating the vehicle on pavement. If it's
unavoidable, travel slowly, travel short
distances and avoid sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets,
roads or highways could result in a collision
with another vehicle. Never operate this
vehicle on any public street, road or highway,
including dirt and gravel roads (unless
designated for off-highway use). In some
areas it's unlawful to operate this vehicle on
public streets, roads and highways.
Operating at Excessive Speeds
Operating this vehicle at excessive speeds
increases the operator's risk of losing
control. Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions and your skills and
experience.
18
SAFETY
Safety Warnings
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this
owner’s manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
Jumps and Stunts
Exhibition driving increases the risk of an
accident or rollover. DO NOT do power slides,
“donuts”, jumps or other driving stunts. Avoid
exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or rollover. Use extreme caution when
operating on hills. Always follow proper
procedures for hill climbing as described in this
owner's manual. See page 58.
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or rollover. Always follow proper
procedures for traveling down hills as
described in this owner’s manual. See page
60.
19
SAFETY
Safety Warnings
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of
control or rollover. Avoid crossing the side of
any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always
follow proper procedures as described in this
owner's manual. See page 59.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a
hill could cause a rollover. Maintain a steady
speed when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle
is fully stopped. Place the transmission in
reverse and slowly allow the vehicle to roll
straight downhill while applying light brake
pressure to control speed.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating
on unfamiliar terrain could result in an
accident or rollover.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of
control or rollover.
Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions.
20
SAFETY
Safety Warnings
Operating Improperly in Reverse
Improperly operating in reverse could result in a
collision with an obstacle or person. Always
follow proper operating procedures as outlined
in this manual. See page 63.
Before shifting into reverse gear, always check
for obstacles or people behind the vehicle.
When it's safe to proceed, back slowly.
Improper Tire Maintenance
Operating this vehicle with improper tires or with improper or uneven tire
pressure could cause loss of control, accident or rollover.
Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in this owner's manual and on safety labels.
Skidding or Sliding
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain
could cause loss of traction, loss of control,
accident or rollover. Do not operate on
excessively slippery surfaces. Always slow
down and use additional caution when
operating on slippery surfaces.
Skidding or sliding due to loss of traction can
cause loss of control or rollover (if tires regain
traction unexpectedly). Always follow proper
procedures for operating on slippery surfaces
as described in this owner's manual. See page 57.
Operating Over Obstacles
Improperly operating over obstacles
could cause loss of control or rollover.
Before operating in a new area, check
for obstacles. Avoid operating over
large obstacles such as large rocks and
fallen trees. Always follow the proper
procedures outlined in this manual
when operating over obstacles. See
page 62.
21
SAFETY
Safety Warnings
Operating Through Water
Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, rollover or accident. Never operate
in fast-flowing water or in water that
exceeds the floor level of the vehicle.
Always follow proper procedures for
operating in water as described in this
owner’s manual. See page 61.
Wet brakes may have reduced stopping
ability. After leaving water, test the brakes. Apply them lightly several times while
driving slowly. The friction will help dry out the pads.
Operating on Frozen Bodies of Water
Severe injury or death can result if the
vehicle and/or the operator fall through the
ice. Never operate the vehicle on a frozen
body of water unless you have first verified
that the ice is sufficiently thick to support
the weight and moving force of the vehicle,
you and your cargo, together with any
other vehicles in your party.
Always check with local authorities and
residents to confirm ice conditions and
thickness over your entire route. Vehicle
operators assume all risk associated with
ice conditions on frozen bodies of water.
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any rollover or
other accident, have a qualified service dealer inspect the entire machine for
possible damage, including (but not limited to) seat belts, rollover protection
devices, brakes, throttle and steering systems.
22
SAFETY
Safety Warnings
Improper Cargo Loading
Overloading the vehicle or carrying/towing cargo improperly may cause
changes in stability and handling, which could cause loss of control or an
accident.
• Always follow the instructions in this owner’s manual for carrying cargo. See
page 64.
• Never exceed the stated load capacity for this vehicle. See page 12.
• Cargo should be properly distributed and securely attached. See page 64.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance
for braking.
Poor Visibility
Operating this vehicle in darkness or inclement weather could result in a
collision or accident, especially if operating on a road or street. This vehicle is
not equipped with highway-approved lights. Operate this vehicle off-road only.
Use caution and drive at reduced speeds in conditions of reduced visibility such
as fog, rain and darkness. Clean headlights frequently and replace burned out
headlamps promptly.
Refueling
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always turn off the engine when refueling.
• Always refuel outdoors or in a well ventilated area free of any source of flame
or sparks.
• Always use an approved gasoline container to store fuel and remove the
container from the vehicle before filling to avoid fuel ignition due to electrical
static discharge.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap and
water and change clothing.
23
SAFETY
Safety Warnings
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass, to
avoid debris build-up around the exhaust system.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 16, without a drivers license, or without proper
training. This could result in an accident or rollover. Always remove the ignition
key when the vehicle is not in use.
Equipment Modifications
Your POLARIS vehicle is designed to provide safe operation when used as
directed. Modifications to your vehicle may negatively impact vehicle stability.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. This vehicle may
become less stable at speeds higher than those for which it is designed. Loss of
control may occur at higher speeds.
Do not install any non-POLARIS-approved accessory or modify the vehicle for
the purpose of increasing speed or power. Any modifications or installation of
non-POLARIS-approved accessories could create a substantial safety hazard
and increase the risk of bodily injury.
The warranty on your POLARIS vehicle will be terminated if any non-POLARIS-
approved equipment and/or modifications have been added to the vehicle that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers, or large racks, may change the handling characteristics
of the vehicle. Use only POLARIS-approved accessories, and familiarize
yourself with their function and effect on the vehicle.
FOR MORE INFORMATION ABOUT SAFETY
call POLARIS at 1-800-342-3764.
24
FEATURES AND CONTROLS
Component Locations
Hip
Bars
Cargo
Box
Shifter
Cab Nets
Steering
Wheel
Throttle
Pedal
Brake
Pedal
ROPS
Frame
Front Box
Cover
Headlights
Taillights
Engine
Intake
Pre-Filter
Radiator
Single-Rider
Seat
Brush Guard
Fuel Cap
25
FEATURES AND CONTROLS
Trailer Receiver Hitch Bracket
This vehicle is equipped with a
receiver hitch bracket for a trailer
hitch. Trailer towing equipment is not
supplied with this vehicle.
To avoid injury and property damage,
always heed the warnings and towing
capacities outlined on pages 64-66.
Service Access Panels
Access serviceable engine
components through the engine access
panel behind the seat. Remove the seat
and release the access panel latches to
remove the access panel.
Remove rear access panel to access the
air box and spark plug. The rear access
panel is located in the bed of the cargo
box. Pull the rear edge of the access
panel upward to remove it.
Radiator Access/Bumper Removal
The front bumper can be
removed to clean debris from
the radiator.
1. Remove the four (4) torx
screws and six (6) plastic
rivets.
2. Lift the front bumper to
remove it from the vehicle.
Receiver Hitch
Rear Access Panel
Screws
Rivets
26
FEATURES AND CONTROLS
Steering Wheel
The steering wheel can be tilted upward or
downward for rider preference.
Lift and hold the steering wheel adjustment
lever while moving the steering wheel
upward or downward. Release the lever when
the steering wheel is at the desired position.
Always make sure the steering wheel
position does not impede proper operation of
the brake pedal, throttle pedal and all other
controls.
Front Box Cover
Remove the front box cover
and access panel to access the
radiator cap, coolant overflow
bottle and brake master
cylinder reservoir.
1. Turn the box cover
fasteners 1/4 turn.
2. Lift the rear edge of the box
cover.
3. Using the pliers provided in
the tool kit, remove the two
(2) push darts from the
access panel. Remove the
panel.
Adjustment
Lever
Cover Fasteners
Access Panel
27
FEATURES AND CONTROLS
Cab Nets
Riding in this vehicle without
using the cab nets (or doors, if
equipped) increases the risk of
serious injury or death in the event
of an accident or rollover. Cab
nets (or doors) must be used at all
times. Make sure all latches on
both sides of the vehicle are secure
before operating the vehicle.
Always inspect cab nets and
latches for tightness, wear and
damage before each use of the
vehicle. Use the strap adjusters to
tighten any loose straps. Promptly
replace worn or damaged cab nets
and latches with new cab nets and
latches. Please see your authorized
POLARIS dealer.
Cab Net Latches
28
FEATURES AND CONTROLS
Fuel Cap
The fuel tank filler cap is located
on the right side of the vehicle
near the seat. When refueling,
always use either leaded or
unleaded gasoline with a
minimum pump octane number
of 87 R+M/2 octane. Do not use
fuel with ethanol content greater
than 10 percent, such as E-85
fuel.
Seat
Seat Adjustments
Always make sure the seat position allows for proper access and
operation of the brake pedal, throttle pedal and all other controls.
The seat release lever is located at the left side of the seat. Push the
release lever downward and slide the seat forward or rearward to the
desired position. Release the lever. The seat will lock into the new
position.
Seat Removal
1. Push the seat release lever
downward and slide the seat
forward until it slides off the
frame.
2. Lift the seat away from the
vehicle.
3. Reverse the procedure to reinstall
the seat.
Fuel Cap
Seat Release
Lever
29
FEATURES AND CONTROLS
Seat Belt
This POLARIS vehicle is equipped with three-point lap and diagonal
seat belts. Always secure the seat belt before riding.
To wear the seat belt properly, follow this procedure:
1. Pull the seat belt latch downward and across your chest toward the
buckle at the inner edge of the seat. The belt should fit snugly across
your hips and diagonally across your chest. Make sure the belt is not
twisted.
2. Push the latch plate into the buckle until it clicks.
3. Release the strap, it will self-tighten.
4. Press the red release latch on the buckle to release the seat belt.
Seat Belt Inspection
Inspect all seat belts for proper operation before each use of the vehicle.
1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's
securely latched.
2. Push the red release latch in the middle of the buckle to make sure it
releases freely.
3. Pull each seat belt completely out and inspect the full length for any
damage, including cuts, wear, fraying or stiffness. If any damage is
found, or if the seat belt does not operate properly, have the seat belt
system checked and/or replaced by an authorized POLARIS dealer.
4. To clean dirt or debris from the
seat belts, sponge the straps
with mild soap and water. Do
not use bleach, dye or
household detergents.Use a
garden hose to flush out the
retractor and latch housing
regularly.
Retractor
Housing
Latch
Housing
30
FEATURES AND CONTROLS
Switches
AWD Switch
12V Accessory
Outlet
Ignition Switch/Light Switch
Instrument Cluster
31
FEATURES AND CONTROLS
Switches
Ignition Switch/Light Switch
Use the ignition switch to start the engine
and to turn the lights on or off. The key
can be removed from the switch when it is
in the OFF position.
All Wheel Drive (AWD) Switch (if equipped)
The AWD Switch has two positions:
• All Wheel Drive (AWD)
• Two Wheel Drive (2WD).
Press the top of the rocker switch to engage All
Wheel Drive. Press the bottom of the switch to
operate in two wheel drive.
See page 35 for AWD operating instructions.
Auxiliary Outlet
The vehicle is equipped with a 12-volt accessory outlet on the dash. Use
the outlet to power an auxiliary light or other optional accessories or
lights. For service, the dash outlet connection is under the dash.
OFF Turn the key to the OFF
position to stop the engine.
Electrical circuits are off.
LIGHTS ON The lights are on. Electrical
circuits are on. Electrical
equipment can be used.
LIGHTS OFF The lights are off. Electrical
circuits are on. Electrical
equipment can be used.
START Turn the key to the START
position to engage the
electric starter. See page 52
for starting procedures.
OFF START
AWD
2WD
32
FEATURES AND CONTROLS
Gear Selector
To change gears, stop the
vehicle, and with the
engine idling, move the
lever to the desired gear.
Do not attempt to shift
gears with engine speed
above idle or while the
vehicle is moving.
P: Park
R: Reverse
N: Neutral
L: Low Gear
H: High Gear
NOTICE: Do not attempt to shift the transmission while the vehicle is moving or
damage to the transmission could result. Always shift when the
vehicle is stationary and the engine is at idle.
Using Low Range
Always shift into low gear for any of the following conditions.
• Operating in rough terrain or over obstacles
• Loading the vehicle onto a trailer
• Towing heavy loads
Gear Selector
33
FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to slow or
stop the vehicle. Apply the brakes
while starting the engine.
Throttle Pedal
Push the pedal down to increase
engine speed. Spring pressure returns
the pedal to the rest position when
released. Always check that the
throttle pedal returns normally before
starting the engine. Make sure there's
adequate throttle pedal freeplay. See
page 106 for throttle pedal adjustment
procedures.
This vehicle is equipped with a throttle release switch, which is
designed to reduce the risk of a frozen or stuck throttle. If the throttle
cable should stick in an open position when the operator releases the
throttle pedal, engine speed will be limited, and power to the rear wheels
will be reduced.
Throttle
Pedal
Brake
Pedal
34
FEATURES AND CONTROLS
Rollover Protective Structure (ROPS)
The Rollover Protective Structure
(ROPS) on this vehicle meets
OSHA 1928.53 rollover
performance requirements. Always
have your authorized POLARIS
dealer thoroughly inspect the ROPS
if it ever becomes damaged in any
way.
No device can assure occupant
protection in the event of a rollover.
When used with seat belts and cab
nets, the ROPS helps prevent
occupants from being ejected from
the vehicle. Always follow all safe
operating practices outlined in this
manual to avoid vehicle rollover.
WARNING! Vehicle rollover could
cause severe injury or death. Always
avoid operating in a manner that could
result in vehicle rollover.
ROPS Label
(on ROPS behind rear cab)
35
FEATURES AND CONTROLS
All Wheel Drive (AWD) System
The All Wheel Drive system is controlled by the
AWD switch. When the switch is on 2WD (2X4),
the vehicle is in two-wheel drive at all times.
When the switch is on AWD (4x4), the vehicle is
in all wheel drive and the 4X4 indicator in the
instrument cluster will be on.
When in AWD, the demand drive unit will
automatically engage any time the rear wheels lose
traction. When the rear wheels regain traction, the
demand drive unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in AWD.
Engaging AWD
The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the demand drive unit is moving, it will not disengage until the
rear wheels regain traction.
Engage the AWD switch before getting into conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.
NOTICE: Switching to AWD while the rear wheels are spinning or slipping may
cause severe drive shaft and gearcase damage. Always switch to
AWD while the rear wheels have traction or are at rest.
AWD
2WD
36
FEATURES AND CONTROLS
Instrument Cluster
High water pressure may damage
components. Wash the vehicle by
hand or with a garden hose using
mild soap. Do not use alcohol to
clean the instrument cluster. Do
not allow insect sprays to contact
the lens.
Speedometer
The speedometer displays vehicle
speed in either miles per hour
(MPH) or kilometers per hour
(km/h). See page 40.
Mode Button
Use the MODE button to toggle
through mode options. See page 40
for operation of the modes.
Rider Information
Center
Speedometer
Indicator
Lamps
MODE
Button
37
FEATURES AND CONTROLS
Instrument Cluster
Indicator Lamps
Lamp Indicates Condition
Vehicle
Speed
When standard mode is selected, speed displays in
miles per hour.
When metric mode is selected, speed displays in
kilometers per hour.
Over
Temperature
This lamp illuminates to indicate an overheated
engine. If the indicator flashes, the overheating
condition remains, and the system will automatically
reduce engine power.
Neutral This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam (if
equipped)
This lamp illuminates when the headlamp switch is
set to high beam.
Helmet/Seat
Belt
This lamp flashes for several seconds when the key is
turned to the ON position. The lamp is a reminder to
wear helmet and seat belt before operating.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.
38
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
The rider information center is located in the instrument cluster. All
segments will light up for one second at start-up. If the instrument
cluster fails to illuminate, a battery over-voltage may have occurred and
the instrument cluster may have shut off to protect the electronic
speedometer. If this occurs, take the vehicle to your POLARIS dealer
for proper diagnosis.
The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 41.
1. Gear Indicator - This indicator displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
-- = Gear Signal Error (or shifter between gears)
Trip 1
km
mi
RPM
FE
88
:
88
1
2
6
5
4
7
3
8
39
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
2. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the
fuel sensor circuit. See your POLARIS dealer.
3. Information Display Area - This area displays odometer, trip
meter, engine hour meter and programmable service hour interval.
4. Under / Over Voltage - This warning usually indicates that the
vehicle is operating at an RPM too low to keep the battery charged.
It may also occur when the engine is at idle and high electrical load
(lights, cooling fan, accessories) is applied. Drive at a higher RPM
or recharge the battery to clear the warning.
5. Clock - The clock displays time in a 12-hour or 24-hour format. See
page 41 for resetting instructions.
6. Service Indicator - A flashing wrench symbol alerts the operator
that the preset service interval has been reached. The vehicle should
be brought to your POLARIS dealer for scheduled maintenance.
See page 41 for resetting instructions.
7. 4X4 Indicator - This indicator illuminates when the 4X4 system is
engaged (switch is on 4X4).
8. Turf Mode Indicator (if equipped) - This indicator illuminates
when the operator unlocks the differential.
40
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Use the MODE button to toggle through the
information area options.
Display Units (Standard/Metric)
The display can be changed to show either
standard or metric units of measurement for
each of the following settings.
Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key
on. The gauge display the mode that was displayed prior to setting the
units.
1. Turn the key to the OFF position.
2. Press and hold the MODE button while turning the key to the ON
position.
3. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting.
4. Press and hold the MODE button to save the setting and advance to
the next display option.
5. Repeat the procedure to change remaining display settings.
Standard Display Metric Display
Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock
MODE
Button
41
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or
discharged.
1. Turn the key to the ON position. Use the MODE button to toggle to
the odometer display.
2. Press and hold the MODE button until the hour segment flashes.
Release the button.
3. With the segment flashing, tap the MODE button to advance to the
desired setting.
4. Press and hold the MODE button until the next segment flashes.
Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.
6. Turn the key to the OFF position.
Odometer Mode
The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode
The trip meter records the distance traveled by the vehicle if reset before
each trip. To reset, select the trip meter mode. Press and hold the MODE
button until the meter resets to zero. In the Rider Information Center, the
trip meter display contains a decimal point, but the odometer displays
without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Engine Temperature Mode
This mode displays current temperature of the coolant.
Tachometer Mode
The engine RPM is displayed digitally.
Tip: Small fluctuations in the RPM from day to day may be normal because of
changes in humidity, temperature and elevation.
42
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Programmable Service Interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is
programmed at 50 hours at the factory. Use the following procedure to
change the service interval.
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.
Diagnostic Display Mode
The EFI diagnostic display mode is for informational purposes only.
Please see your POLARIS dealer for all major repairs.
The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if
you want to view the active code (failure code).
The diagnostic mode becomes inaccessible if the key is turned off and
on and the warning indicator is no longer active. This allows the
determination of persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
43
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Engine Error Codes
The error screen displays
only when the CHECK
ENGINE light is on or
when it goes on and off
during one ignition cycle.
Error codes are not stored.
When the key is turned
OFF, the code and
message is lost, but will
reappear if the fault
reoccurs after restarting
the engine.
If the CHECK ENGINE
light illuminates, retrieve
the error codes from the
display.
1. If the error codes are not displayed, use the MODE button to toggle
until “Ck ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code
menu.
3. Record the three numbers displayed in the gear position, clock and
odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. See pages 44-45 for code definitions and failure descriptions. Please
see your POLARIS dealer for all major repairs.
Suspect Parameter
Number (SPN)
Error Code
Number (0-9)
Failure Mode Indicator (FMI)
44
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Open Load: There is a break in the wires that lead to the item listed in
the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground
: The wire is shorted to ground between the electronic
control unit and the item listed in the chart.
Shorted Load
: The wires leading to the item listed in the chart are
shorted together, or the item has shorted internally.
Short-to-Battery
: The wire leading from the item listed in the chart to
the electronic control unit is shorted to a wire at battery voltage.
45
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
*Assumes unipolar configuration of stepper motor
Diagnostic Codes
Component Condition SPN FMI
Throttle Position Sensor
Voltage Too High 51 3
Voltage Too Low 51 4
Engine Temperature Sensor
Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0
Intake Air Temperature Sensor
Voltage Too High 105 3
Voltage Too Low 105 4
Manifold Absolute Pressure Sensor
Voltage Too High 102 3
Voltage Too Low 102 4
Crankshaft Position Sensor Circuit Fault 636 8
Gear Sensor Signal Voltage Too Low (to Calibrate) 523 4
Voltage Too High 523 3
Signal Fault 523 2
Injector 1 (MAG) Driver Circuit Open/Grounded 651 5
Driver Circuit Short to B+ 651 3
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5
Driver Circuit Short to B+ 1268 3
Fuel Pump Driver Circuit
Driver Circuit Open/Grounded 1347 5
Driver Circuit Short to B+ 1347 3
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5
Driver Circuit Short to B+ 1071 3
Idle Air Control Driver Circuit Grounded 520193 5
Shorted Load* 520193 11
Starter Enable Circuit Driver Circuit Short to B+ 1321 3
All Wheel Drive Control Driver Circuit Short to B+ 520207 3
System Power Voltage Too High 168 3
Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3
Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7
Active Descent Control System Driver Circuit Short to B+ 520203 3
46
OPERATION
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Vehicle Break-in Period
The break-in period for your new POLARIS vehicle is the first 25 hours
of operation, or the time it takes to use the first two tanks full of
gasoline. No single action on your part is as important as a proper break-
in period. Careful treatment of a new engine and drive components will
result in more efficient performance and longer life for these
components. Perform the following procedures carefully.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
Use of any oils other than those recommended by POLARIS may
cause serious engine damage. We recommend the use of POLARIS
PS-4 Full Synthetic 5W-50 4-Cycle Oil for your 4-cycle engine.
WARNING
47
OPERATION
Vehicle Break-in Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 28. Always exercise
extreme caution whenever handling gasoline.
2. Check the oil level. See page 87. Add the recommended oil as
needed to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined on pages
54-55.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained idle.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 48.
8. During the break-in period, change both the oil and the filter at 25
hours or one month.
9. Check fluid levels of transmission and all gearcases after the first 25
hours of operation and every 100 hours thereafter.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive or
overly forceful braking when the brake system is new could damage
brake pads and rotors.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation
during the break-in period.
If a belt fails, always clean any debris from the PVT intake and outlet
duct and from the clutch and engine compartments when replacing the
belt.
48
OPERATION
Pre-Ride Inspection
Failure to inspect and verify that the vehicle is in safe operating
condition before operating increases the risk of an accident. Always
inspect the vehicle before each use to make sure it's in safe operating
condition.
Item Remarks Page
Brake system/pedal travel Ensure proper operation 33
107
Brake fluid Ensure proper level 108
Front suspension Inspect, lubricate if necessary 84
Rear suspension Inspect, lubricate if necessary 84
Steering Ensure free operation 110
Tires Inspect condition and pressure 12
111
Wheels/fasteners Inspect, ensure fastener tightness 111
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 39
87
Coolant level Ensure proper level 98
97
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 105
Indicator lights/switches Ensure proper operation 31
Air filter, pre-filter Inspect, clean 102-
103
Intake pre-filters Inspect, clean 103
Headlamps Check operation, apply POLARIS
dielectric grease when lamp is
replaced
113
Brake light/tail lamps Check operation, apply POLARIS
dielectric grease when lamp is
replaced
115
Seat Latch Push down on the seat back to
ensure the latch is secure
28
Seat Belt Check length of belt for damage,
check latches for proper operation
29
Cab Nets Check for wear or damage, ensure
proper installation
27
49
OPERATION
Know Your Riding Area/Tread Lightly
Familiarize yourself with all laws and regulations concerning the
operation of this vehicle in your area. Respect the environment in which
you ride your vehicle. Find out where the designated riding areas are by
contacting your POLARIS dealer, a local riding club, or local officials.
Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.
Trail Etiquette
Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi-
cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.
50
OPERATION
Safe Operation Practices
1. Visit the Recreational Off-Highway Vehicle Association web site
and take the free on-line training course. Complete the
recommended safety training before operating this vehicle. Visit
www.rohva.org or call 866-267-2751.
2. Do not allow anyone under 16 years of age or without a valid
driver’s license to operate this vehicle.
3. Never carry a passenger on this vehicle.
4. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
5. Never operate with accessories not approved by POLARIS for use
on this vehicle.
6. Operate this vehicle off-road only. Never operate this vehicle on any
public street, road or highway, including dirt and gravel roads
(unless designated for off-highway use).
7. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights
frequently and replace burned out headlamps promptly.
8. Always operate at a speed that's appropriate for the terrain, the
visibility and operating conditions and your skills and experience.
Never operate at excessive speeds. Never attempt wheelies, jumps,
or other stunts. Keep both hands on the steering wheel during
operation.
9. Never consume alcohol or drugs before or while operating this
vehicle.
51
OPERATION
Safe Operation Practices
10. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
11. Never operate a damaged vehicle. After any rollover or accident,
have a qualified service dealer inspect the entire machine for
possible damage.
12. Never operate the vehicle on a frozen body of water unless you have
first verified that the ice is sufficiently thick to support the weight
and moving force of the vehicle, you and your cargo, together with
any other vehicles in your party.
13. Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system.
14. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
52
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-
ventilated area.
2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets.
3. Place the transmission in PARK.
4. Apply the brakes. Do not press the throttle pedal while starting the
engine.
5. Turn the ignition key to the START
position. Engage the starter for a
maximum of five seconds. Release
the key when the engine starts. Turn
the key to either LIGHTS ON or
LIGHTS OFF.
6. If the engine does not start within
five seconds, return the ignition
switch to the OFF position and wait
five seconds. Repeat steps 5 and 6
until the engine starts.
7. Vary the engine RPM slightly with
the throttle to aid in warm up until the engine idles smoothly.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
Cold Weather Operation
If the vehicle is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminates such as water
or excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water
accumulation increases as outside temperature decreases.
OFF START
53
OPERATION
Stopping the Engine
1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the engine off.
Braking
1. Release the throttle pedal completely. (When the throttle pedal is
released completely and engine speed slows to near idle, the vehicle
has no engine braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and
stopping (using the brakes) until you're familiar with the controls.
Parking the Vehicle
1. Stop the vehicle on a level surface. When parking inside a garage or
other structure, be sure that the structure is well ventilated and that
the vehicle is not close to any source of flame or sparks, including
any appliance with pilot lights.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Remove the ignition key to prevent unauthorized use.
54
OPERATION
New Operator Driving Procedures
1. Read and understand the owner's manual and all warning and
instruction labels before operating this vehicle.
2. Visit the Recreational Off-Highway Vehicle Association web site
and take the free on-line training course. Visit www.rohva.org or
call 866-267-2751. Hands-on training is also available through
ROHVA.
3. Perform the pre-ride inspection. See page 48.
4. Do not tow or carry cargo during this period.
5. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.
6. The driver must wear helmet, eye protection, gloves, long-sleeve
shirt, long pants, over-the-ankle boots and seat belt at all times.
7. Sit in the driver's seat and fasten the seat belt.
8. Make sure all cab nets are properly secured.
9. Place the transmission in PARK.
10. Start the engine.
55
OPERATION
New Operator Driving Procedures
11. Apply the brakes and shift into low gear.
12. Check your surroundings and determine your path of travel.
13. Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving.
14. Drive slowly at first. On level surfaces, practice starting, stopping,
turning, maneuvering, using the throttle and brakes and driving in
reverse. Learn how the vehicle handles when making both left and
right turns at a slow speed.
WARNING! Operating in TURF mode (if equipped) when on sloped, uneven, or
loose terrain could cause loss of control and result in serious injury or death.
One rear wheel may slip and lose traction or may lift up and grab when it
touches the ground again.
15. Increase speed only after mastering all maneuvers at a slow speed.
16. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions:
• Avoid sharp turns.
• Never turn while applying heavy throttle.
• Never make abrupt steering maneuvers.
• Operate at speeds appropriate for your skills, the conditions and
the terrain.
• DO NOT do power slides, “donuts”, jumps or other driving
stunts.
56
OPERATION
Turning the Vehicle
Your vehicle is equipped with a
solid rear axle, which drives both
rear wheels equally at all times.
This means that the wheel on the
outside of the turn must travel a
greater distance than the inside
wheel when turning and the inside
tire must slip traction slightly.
To turn the vehicle, rotate the
steering wheel in the direction of
the turn.
Practice making turns at slow
speeds before attempting to turn at
faster speeds.
WARNING! Turning improperly can
result in vehicle rollover. Never turn
abruptly or at sharp angles. Never turn
at high speeds.
57
OPERATION
Driving on Slippery Surfaces
When driving on slippery surfaces such as wet trails, loose gravel, or
ice, be alert for the possibility of skidding and sliding. Follow these
precautions when encountering slippery conditions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down before entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
4. Engage all-wheel drive before wheels begin to lose traction.
NOTICE: Severe damage to the drive train may occur if the AWD is engaged
while the wheels are spinning. Always allow the wheels to stop
spinning before engaging AWD.
5. Correct a skid by turning the steering wheel in the direction of the
skid. Never apply the brakes during a skid.
Sideways
skid
Turn in
direction of
skid
58
OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always check the terrain carefully before ascending any hill. Never
drive on hills with excessively slippery or loose surfaces.
2. Never operate in TURF mode (if equipped) while operating on a hill
or other irregular terrain. Always move the AWD switch to AWD
before ascending or descending a hill.
3. Avoid excessively steep hills. If ascending a steeper grade is
unavoidable, engage all-wheel drive before ascending.
4. Drive straight uphill.
5. Proceed at a steady rate of speed and throttle opening. Never open
the throttle suddenly.
6. Avoid unnecessary changes in speed or direction.
7. Never go over the crest of a hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.
8. If the vehicle stalls while climbing a hill, apply the brakes. Place the
transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to control speed.
59
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or rollover. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a hill is unavoidable, follow these precautions:
1. Engage all-wheel drive.
2. Never operate in TURF mode (if equipped) while operating on a hill
or other irregular terrain. Always move the AWD switch to AWD
before ascending or descending a hill.
3. Drive slowly and use extreme caution.
4. If the vehicle begins to overturn, or if it feels as if it may overturn,
immediately turn downhill.
5. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide.
6. If the vehicle begins to slide downhill, immediately turn downhill to
stop the slide, or stop the vehicle and maneuver slowly and
carefully until the vehicle can be driven straight downhill.
60
OPERATION
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Avoid excessively steep hills.
2. Never operate in TURF mode (if equipped) while operating on a hill
or other irregular terrain. Always move the AWD switch to AWD
before ascending or descending a hill.
3. Slow down. Never travel down a hill at high speed.
4. Always check the terrain carefully before descending a hill. Never
drive on hills with excessively slippery or loose surfaces.
5. Always descend a hill with the transmission in forward gear. Never
descend a hill with the transmission in neutral.
6. Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight downhill.
7. Apply the brakes lightly to aid in slowing.
61
OPERATION
Driving Through Water
Your vehicle can operate
through water with a
maximum recommended depth
equal to floor level. Follow
these precautions when
operating through water:
1. Determine water depth and
current before entering
water.
2. Choose a crossing where
the water level is lowest
and where both banks
have gradual inclines.
Never operate in water that
exceeds the maximum
recommended depth.
WARNING! The large tires on your vehicle may cause the vehicle to float in
deep or fast-flowing water, which could result in loss of traction, loss of control,
rollover or accident.
3. Wet brakes may have reduced stopping ability. After leaving water,
test the brakes. Apply them lightly several times while driving
slowly. The friction will help dry out the pads.
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 79. Give special attention to engine
oil, transmission oil, demand drive fluid, rear gearcase oil (if
equipped) and all grease fittings.
If your vehicle becomes immersed or is operated in water that
exceeds the floor level, take it to your POLARIS dealer for service
before starting the engine. If it's impossible to bring the vehicle to
your dealer before starting the engine, perform the service outlined
on page 115, and take the vehicle to your dealer at the first
opportunity.
Floor Level
62
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for
hazards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
4. Avoid operating over large obstacles such as large rocks and fallen
trees. If unavoidable, use extreme caution and operate slowly.
63
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Apply the throttle lightly. Never apply throttle suddenly.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid making sharp turns.
Parking on an Incline
A rolling vehicle can result in
serious injury. Avoid parking on
an incline. If parking on an
incline is unavoidable, follow
these precautions:
1. Place the transmission in
PARK.
2. Turn the engine off.
3. Block the rear wheels on the
downhill side, or park the
vehicle in a sidehill position
instead.
64
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:
Never exceed the stated load capacity for this vehicle.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.
Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.
Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing vehicle
rollover.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 MPH (16 km/h) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads
in rough terrain, while cornering, or while ascending or descending a hill.
Carrying a passenger in the cargo box could
result in a fall from the vehicle or contact with
moving components. Never allow a
passenger to ride in the cargo box.
WARNING
65
OPERATION
Hauling Cargo
Your POLARIS vehicle has been designed to carry or tow specific
capacities. Reduce speed and allow a greater distance for braking when
carrying cargo.
Loads should be centered and carried as low as possible in the box. For
stability on rough or hilly terrain, reduce both speed and cargo. Exercise
caution if the cargo load extends over the side of the box.
Always read and understand the load distribution warnings listed on
warning labels and in this manual. Never exceed the maximum
capacities specified for your vehicle. See page 128.
Belt Life
To extend belt life, use low gear when hauling or towing heavy cargo.
66
OPERATION
Towing Loads
Towing improperly can alter vehicle handling and may cause loss of control or
brake instability.
Always follow these precautions when towing:
1. Never load more than 150 lbs. (68.1 kg) tongue weight on the
towing bracket.
2. When towing a disabled vehicle, place the disabled vehicle’s
transmission in neutral. Do not operate the vehicle faster than 10
MPH (16 km/h) when towing.
3. Towing a trailer increases braking distance. Do not operate the
vehicle faster than 10 MPH (16 km/h) when towing.
4. Do not tow more than the recommended weight for the vehicle.
5. Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location, which could result in loss of control of
the vehicle.
6. The total load (operator, accessories, cargo and weight on hitch)
must not exceed the maximum weight capacity of the vehicle.
Total Towed
Load Weight
(Level Ground)
Total Towed
Load Weight
(15° grade)
Total Hitch
Vertical
Weight
Maximum
Towing
Speed
1500 lbs.
(681 kg)
850 lbs.
(386 kg)
150 lbs.
(68.1 kg)
10 MPH
(16 km/h)
WARNING
67
WINCH GUIDE
These safety warnings and instructions apply if your vehicle came
equipped with a winch or if you choose to add an accessory winch to
your vehicle.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially
designed synthetic rope. The term “winch cable” will be used for either
unless noted otherwise.
Winch Safety Precautions
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the
winch.
5. Always keep body, hair, clothing and jewelry clear of the winch
cable, fairlead and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving
vehicle. See the Shock Loading section on page 76.
7. Always keep the area around the vehicle, winch, winch cable and
load clear of people (especially children) and distractions while
operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch
are not being used.
9. Always be sure that at least five (5) full turns of winch cable are
wrapped around the winch drum at all times. The friction provided
by this wrapped cable allows the drum to pull on the winch cable
and move the load.
WARNING
68
WINCH GUIDE
Winch Safety Precautions
10. Always apply your vehicle’s park brake and/or park mechanism to
hold the vehicle in place during winching. Use wheel chocks if
needed.
11. Always align the vehicle and winch with the load directly in front of
the vehicle as much as possible. Avoid winching with the winch
cable at an angle to the winching vehicle’s centerline whenever
possible.
12. If winching at an angle is unavoidable, follow these precautions:
A. Look at the winch drum occasionally. Never let the winch cable “stack”
or accumulate at one end of the winch drum. Too much winch cable at
one end of the winch drum can damage the winch and the winch cable.
B. If stacking occurs, stop winching. Follow step 15 on page 74 to feed
and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the
winching vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s
rated capacity.
15. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation,
stop winching and permit the winch to cool down for 10 minutes
before using it again.
16. Never touch, push, pull or straddle the
winch cable while winching a load.
17. Never let the winch cable run through
your hands, even if wearing heavy
gloves.
69
WINCH GUIDE
Winch Safety Precautions
18. Never release the clutch on the winch when the winch cable is under
load.
19. Never use the winch for lifting or transporting people.
20. Never use the winch to hoist or suspend a vertical load.
21. Never immerse or submerse your winch in water. Take your winch
to your dealer for service if this occurs.
22. Always inspect your winch and winch cable before each use.
23. Never winch the hook fully into the winch. This can cause damage
to winch components.
24. Unplug the remote control from the vehicle when the winch is not in
use to prevent inadvertent activation and use by unauthorized
persons.
25. Never grease or oil the winch cable. This will cause the winch cable
to collect debris that will shorten the life of the cable.
70
WINCH GUIDE
Winch Operation
Read the Winch Safety Precautions in the preceding pages before using
your winch.
Tip: Consider practicing the operation and use of your winch before you actually
need to use it in the field.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able
to deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls
for any signs of damage or parts in need of repair or replacement
before each use. Pay particular attention to the first 3 feet (1 meter)
of winch cable if the winch is being used (or has been used) for lift-
ing an accessory plow assembly. Promptly replace any worn or
damaged cable.
2. Never operate a winch or a vehicle in need of repair or service.
3. Always apply your
vehicle’s park brake and/
or park mechanism to hold
the vehicle in place during
winching. Use wheel
chocks if needed.
WARNING
Hook Strap
71
WINCH GUIDE
Winch Operation
4. Always use the hook strap when
handling the hook.
WARNING! Never put your fingers into
the hook. This could lead to SEVERE
INJURY.
A. Attach the hook itself onto the
load or use a tow strap or chain
to secure the load to the winch
cable.
Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to
stretch.
WARNING! Never use a recovery strap when winching due to the excessive
energy that can be released if the winch cable breaks. This can result in
SEVERE INJURY or DEATH. See the Shock Loading section on page 76.
B. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.
WARNING! Replace the winch cable at the first sign of damage to prevent
SEVERE INJURY or DEATH in the event of failure. For your safety, always
replace POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer.
C. If possible, keep the winch cable aligned with the centerline of the
winching vehicle. This will help the spooling of the winch cable and
reduce the load on the fairlead.
D. If freeing a stuck vehicle by attaching to a tree, use an item such as a
tow strap to avoid damaging the tree during winch operation. Sharp
cables and chains can damage and even kill trees. Please remember
to TreadLightly® (treadlightly.org).
E. Before operating the winch, be sure
that the safety latch on the winch
cable hook is fully seated when the
load is attached.
F. Never operate your winch with a
damaged hook or latch. Always
replace damaged parts before using
the winch.
NO YES
NO
YES
72
WINCH GUIDE
Winch Operation
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the winch’s pulling
capacity. Always be sure that at least five (5) full turns of winch
cable are wrapped around the winch drum at all times. The friction
provided by this wrapped cable allows the drum to pull on the
winch cable and move the load.
8. Read and adhere to the following information for winch damping to
ensure safe winch use.
A. In order to absorb energy that could be released by a winch cable
failure, always place a “damper” on the winch cable. A damper can be
a heavy jacket, tarp, or other soft, dense object. A damper can absorb
much of the energy released if a winch cable breaks when winching.
Even a tree limb can help as a damper if no other items are available to
you.
B. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
C. On a long pull, it may be necessary to stop winching so that the
damper can be repositioned to the new mid-point of the winch cable.
Always release the tension on the winch cable before repositioning the
damper.
D. Avoid being directly in line with the winch cable whenever possible.
Also, never permit others to stand near or in line with the winch cable
during winch operation.
9. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or
worn.
73
WINCH GUIDE
Winch Operation
11. The ONLY time a winch-equipped vehicle should be moving when
using the winch is when that vehicle itself is stuck. The winch-
equipped vehicle should NEVER be in motion to “shock” load the
winch cable in an attempt to move a second stuck vehicle. See the
Shock Loading section on page 76. For your safety, always follow
these guidelines when winching a vehicle free:
A. Release the winch clutch and spool out the necessary length of winch
cable.
B. Align the winch cable as close as possible to the winching vehicle’s
centerline.
C. Attach the winch cable hook to the anchor point or the stuck vehicle’s
frame following instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle gear to propel the stuck vehicle in the
direction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free
the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself
without the help of the winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12. Never attempt to winch another stuck vehicle by attaching the
winch cable to a suspension component, brush guard, bumper or
cargo rack. Vehicle damage may result. Instead, attach the winch to
a strong portion of the vehicle frame or hitch.
13. Extensive winching will run down the battery on the winching
vehicle. Let the winching vehicle’s engine run while operating the
winch to prevent the battery from running low if winching for long
periods.
74
WINCH GUIDE
Winch Operation
14. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation,
stop winching and permit the winch to cool down for 10 minutes
before using it again.
15. After winching is complete, especially if winching at an angle, it
may be necessary to re-distribute the winch cable across the winch
drum. You will need an assistant to perform this task.
A. Release the clutch on the winch.
B. Feed out the winch cable that is unevenly bunched up in one area.
C. Re-engage the winch clutch.
D. Have an assistant pull the winch cable tightly with about 100 lbs. (45
kg) of tension using the hook strap.
E. Slowly winch the cable in while your assistant moves the end of the
winch cable back and forth horizontally to evenly distribute the winch
cable on the drum.
F. Doing this reduces the chances of the winch cable “wedging” itself
between lower layers of winch cable.
75
WINCH GUIDE
Winch Cable Care
For your safety, always replace POLARIS winch parts (including the
cable) with genuine POLARIS replacement parts available at your
authorized POLARIS dealer.
WARNING! Use of worn or damaged cable could lead to sudden failure and
SEVERE INJURY.
1. Always inspect your winch before each use. Inspect for worn or
loose parts including mounting hardware. Never use the winch if
any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn
or kinked winch cable.
A. A kinked winch cable made of
wire rope is shown at right. Even
after being “straightened out,”
this cable has already been
permanently and severely
damaged. Promptly discontinue
use of a winch cable in this
condition.
B. A kinked winch cable made of
wire rope that has been
“straightened out” is shown at
right. Even though it may look
usable, the cable has been
permanently and severely damaged. It can no longer transmit the load
that it could prior to kinking. Promptly discontinue use of a winch cable
in this condition.
C. A winch cable made of
synthetic rope should be
inspected for signs of fraying.
Replace the cable if fraying is
observed (shown at right).
Promptly discontinue use of a
winch cable in this condition.
D. Also replace the winch cable if there are fused or melted fibers. Such
an area of the synthetic rope will be stiff and appear smooth or glazed.
Promptly discontinue use of a winch cable in this condition.
A
B
C
76
WINCH GUIDE
Shock Loading
WARNING! Your winch cable is very strong but it is NOT designed for dynamic,
or “shock” loading. Shock loading may tension a winch cable beyond its strength
and cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both
wire-rope and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never
take up slack in the winch cable by moving the winching vehicle in
an attempt to move an object. This is a dangerous practice. It gener-
ates high winch cable loads that may exceed the strength of the
cable. Even a slowly moving vehicle can create large shock loads in
a winch cable.
WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).
This puts extra load on the winch, winch cable, and generates
excessive heat from the motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an
object with a winch produces shock loading of the cable even when
towing at slow speeds. Towing from a winch also positions the
towing force high on the vehicle. This can cause instability of the
vehicle and possibly lead to an accident.
4. Never use recovery straps with your winch. Recovery straps are
designed to stretch and can store energy. This stored energy in the
recovery strap is released if a winch cable fails making the event
even more hazardous. Similarly, never use elastic “bungie” cords
for winching.
5. Never use the winch to tie down a vehicle to a trailer or other
transportation vehicle. This type of use also causes shock loading
that can cause damage to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads
produced by the winch motor when operated from a stationary
vehicle. Always remember that the winch and winch cable are NOT
designed for shock loading.
77
WINCH GUIDE
Winch Maintenance and Service Safety
WARNING! Improper or lack of winch maintenance and service could lead to
SEVERE INJURY or DEATH. Always follow all winch instructions and warnings
in this manual.
1. Always inspect your winch before each use. Inspect for worn or
kinked winch cable. Also inspect for worn or loose parts including
mounting hardware.
2. Permit your winch motor to cool down prior to servicing your
winch.
3. Never work on your winch without first disconnecting the battery
connections to prevent accidental activation of the winch
4. For your safety, always replace POLARIS winch parts (including
the cable) with genuine POLARIS replacement parts available at
your authorized POLARIS dealer.
5. Some winch models use wire rope as the winch cable. Other
winches use a specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade
polymer rope such as can be purchased in a hardware store.
Although they may look similar, they are NOT alike. A polymer
rope not designed for winch use will stretch and store excessive
energy when winching.
WARNING! Failure of a stretched rope under winching conditions will release
all of the stored energy. This will increase the chances of SEVERE INJURY or
DEATH.
78
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and qualified
to be in accordance with the USFS standard 5100-1C. Federal law
requires that this spark arrester be installed and functional when the
vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by
engine design. An electronic fuel
injection (EFI) system controls fuel
delivery. The engine and EFI
components are set at the factory for
optimal performance and are not
adjustable.
The emissions label is located on the inside of the lower left frame tube
(below driver’s foot area).
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European
directives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the
limitations of their device and the applicable electromagnetic standards
and directives that apply to this vehicle.
Emissions Label
(inside of frame tube)
79
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.
Record maintenance and service in the Maintenance Log beginning on
page 142.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected and
serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Frequent or prolonged operation in dusty environments
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise.
Monitor the oil level, and if it continues to rise, discontinue use and
determine the cause or see your POLARIS dealer.
80
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
WARNING! Improperly performing the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an
authorized POLARIS dealer perform these services.
Symbol Description
Ź Perform these operations more often for vehicles subjected to severe use.
E Emission-related service (failure to conduct this maintenance will not void
the emissions warranty but may affect emissions)
D Have an authorized POLARIS dealer perform these services.
81
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles (Km)
Steering
Pre-Ride
Inspect and make
adjustments as need ed.
See Pre-Ride Checklist on
page 48.
Front suspension
Rear suspension
Tires
Brake fluid level
Brake pedal travel
Brake system
Wheels/fasteners
Frame fasteners
Engine oil level
Intake pre-filters
Winch (if
equipped)
- - See pages 67-77
Coolant - Daily - Check level daily, change
coolant every 2 years
Headlamp/tail
lamp
- Daily - Check operation; apply
dielectric grease if replacing
Ź
E
Air filter,
main element
- Weekly - Inspect; replace as needed
Ź
D
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Ź
E
Engine breather 25 H Monthly 150 (250) Inspect; replace if necessary
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Ź Engine oil change 25 H 1 M - Break-in oil and filter change
Ź Demand drive fluid 25 H 1 M - Break-in oil level check
Ź Transmission oil
(main gearcase)
25 H 1 M - Break-in oil level check
82
MAINTENANCE
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles (Km)
Ź
E
Throttle cable 50 H 6 M 300 (500) Inspect; adjust; lubricate;
replace if necessary
E Throttle body air
intake ducts/flange
50 H 6 M 300 (500) Inspect duct for proper seal-
ing/air leaks
Ź General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Ź Oil lines, fasteners
(if equipped)
50 H 6 M 500 (800) Inspect for leaks and loose
fittings
Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust
D Steering 50 H 6 M 500 (800) Lubricate
Ź Front Suspension 50 H 6 M 500 (800) Lubricate
Ź Rear Suspension 50 H 6 M 500 (800) Lubricate
Cooling system 50 H 6 M 500 (800) Inspect coolant strength
seasonally; pressure test
system yearly
Ź Engine oil change 100 H 6 M - Change the oil and filter
D
E
Fuel system 100 H 12 M 600 (1000) Check for leaks at tank cap,
lines, filter, pump, throttle
body; replace lines every two
years
Ź
E
Spark plug 100 H 12 M 600 (1000) Inspect; replace as needed
Ź Demand drive fluid 100 H 12 M - Change fluid
Ź Transmission oil
(main gearcase)
100 H 12 M - Change fluid
83
MAINTENANCE
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles (Km)
Ź Radiator 100 H 12 M 1000 (1600) Inspect; clean external
surfaces
Ź Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
Ź Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
Ź Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
Drive belt 100 H 12 M 1000 (1600) Inspect; replace as needed
D Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
D Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrester 300 H 36 M 3000 (4800) Clean out
Ź
E
Valve clearance 500 H - 5000 (8000) Inspect; adjust as needed
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
84
MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.
Item Lube Method
Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick.
See page 87.
Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines.
See page 108.
Transmission Oil
(Main Gearcase)
AGL Gearcase Lubricant &
Transmission Fluid
See page 91.
Demand Drive Fluid
(Front Gearcase)
Demand Drive Fluid See page 90.
Prop Shaft U-Joint Grease Locate fittings and grease.
Rear Control Arm Pivot
Bushings, Front A-Arm
Bushings
All Season Grease or grease
conforming to NLGI No. 2
Locate fittings and grease.
Stabilizer Bar Bushings,
Tie Rod Bushings, Ball
Joint Boots
All Season Grease or grease
conforming to NLGI No. 2
Locate fittings and grease.
Prop Shaft
Grease Fitting
85
MAINTENANCE
Lubrication Recommendations
Rear Control
Arm Pivot
Bushings
Stabilizer Bar
Bushings
Front A-Arm
Bushing
Tie Rod
Bushing
Ball Joint
Boot
86
MAINTENANCE
Engine Oil
Oil Recommendations
POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-
50 4-cycle oil for this engine.
WARNING! Vehicle operation with insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and may result in engine seizure,
accident, and injury. Always perform the maintenance procedures as outlined in
the Periodic Maintenance Chart.
Oil may need to be changed more frequently if POLARIS PS-4 engine
oil is not used. Follow the manufacturer's recommendations for ambient
temperature operation. See page 130 for the part numbers of POLARIS
products.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
87
MAINTENANCE
Engine Oil
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 79. Always use the recommended
engine oil.
NOTICE: Allowing dirt or debris to enter the engine can result in serious engine
damage. Always clean away all dirt and debris from the dipstick area
before removing the dipstick.
Oil Check
The oil dipstick is located on the
lower engine, behind the seat.
Access the dipstick through the right
rear wheel well. Remove the
dipstick to check the oil level and to
add oil. An additional oil fill hole is
located at the top of the engine. Add
oil through either the dipstick hole
or the upper fill hole. Access the
upper fill hole cap through the cargo
box access panel.
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Always clean away all dirt and
debris from the dipstick area
before removing the dipstick.
Remove the dipstick. Wipe it
dry with a clean cloth.
4. Reinstall and tighten the
dipstick.
5. Remove the dipstick and check
the oil level.
6. Add the recommended fluid as
needed. Maintain the oil level in
the safe range between the
FULL and ADD marks. Do not
overfill.
7. Reinstall and tighten the dipstick.
Oil Dipstick (Check/Fill)
Upper Oil Fill
Full
Add
88
MAINTENANCE
Engine Oil
Oil and Filter Change
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 79. Always change the oil filter
whenever changing oil.
The engine drain plug is located
on the bottom of the crankcase.
1. Position the vehicle on a level
surface. Place the
transmission in PARK. Apply
the brakes.
2. Start the engine. Allow it to
idle for two to three minutes.
Stop the engine.
3. Clean the area around the
drain plug.
CAUTION! Hot oil can cause burns
to skin. Do not allow hot oil to contact
skin.
4. Place a drain pan beneath
engine crankcase and remove
the drain plug.
5. Allow the oil to drain
completely.
6. Install a new sealing washer
on the drain plug.
Tip: The sealing surfaces on drain
plug and crankcase should be
clean and free of burrs, nicks or
scratches.
7. Reinstall the drain plug. Torque to 11-13 ft. lbs. (14.5-17.5 Nm).
Spring
Filter
Sealing
Washer
Drain
Plug
O-Ring
Filter Cover
89
MAINTENANCE
Engine Oil
Oil and Filter Change
8. Using a clean dry cloth, clean the oil filter cover on the crankcase.
9. Place shop towels beneath the filter cover to catch oil drips. Remove
the cover screws and remove the cover to access the oil filter.
10. Remove the oil filter and spring, retaining the spring for
reinstallation.
11. Using a clean dry cloth, clean the surface of the crankcase.
12. Lubricate the o-ring for the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition. Install the o-
ring to the filter cover.
13. Reinstall the oil filter spring, then install the new filter.
14. Reinstall the oil filter cover and o-ring. Torque the screws to 88 in.
lbs. (10 Nm).
15. Fill the sump with 1.75 quarts (1.65 l) of the recommended oil.
16. Reinstall the upper fill cap (if removed) and tighten the dipstick.
17. Make sure the transmission is in PARK. Apply the brakes.
18. Start the engine. Allow it to idle for one to two minutes.
19. Stop the engine. Inspect for leaks.
20. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.
21. Dispose of used filter and oil properly.
90
MAINTENANCE
Gearcases
Demand Drive Unit (Front Gearcase)
Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Refer to the
Gearcase Specifications Chart on page 92 for recommended lubricants,
capacities and torque specifications.
Fluid Check
The fill plug is located on the
bottom right side of the
demand drive unit. Access the
fill plug through the right front
wheel well. Maintain the fluid
level even with the bottom
thread of the fill plug hole.
1. Position the vehicle on a
level surface.
2. Remove the fill plug.
Check the fluid level.
3. Add the recommended
fluid to the bottom thread
of the fill plug hole.
4. Reinstall the fill plug.
Torque to specification.
Fluid Change
The drain plug is located on the bottom of the gearcase.
1. Remove the fill plug.
2. Place a drain pan under the drain plug.
3. Remove the drain plug. Allow the fluid to drain completely.
4. Clean the drain plug. If the o-ring is damaged, install a new o-ring.
5. Reinstall the drain plug. Torque to specification.
6. Add the recommended fluid to the bottom thread of the fill plug
hole.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Discard used fluid properly.
Fill Level
Fill Plug
Drain Plug
91
MAINTENANCE
Gearcases
Transmission (Main Gearcase)
Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Refer to the
Gearcase Specifications Chart on page 92 for recommended lubricants,
capacities and torque specifications.
Fluid Check
The fill plug is located on the rear of
the gearcase. Maintain the fluid level at
the bottom of the fill plug hole.
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the
fluid level.
3. Add the recommended fluid to the
bottom of the fill plug hole. Do not
overfill.
4. Reinstall the fill plug. Torque to
specification.
Fluid Change
The drain plug is located on the bottom
of the gearcase between the rear tires.
Access the drain plug through the drain
hole in the skid plate.
1. Remove the fill plug.
2. Place a drain pan under the drain
plug. Remove the drain plug. Allow the fluid to drain completely.
3. Clean the drain plug. Reinstall the drain plug with a new o-ring.
Torque to specification.
4. Add the recommended fluid to the bottom of the fill plug hole. Do
not overfill.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Discard used fluid properly.
Fill Plug
Drain Plug
(between rear tires)
92
MAINTENANCE
Gearcases
Gearcase Specification Chart
Use of other fluids may result in improper operation of components. See
page 130 for the part numbers of POLARIS products.
Spark Plug
Spark Plug Gap/Torque
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs. Refer to
the specifications section beginning on page 128.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 93.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
Gearcase Lubricant Capacity Fill Plug
Torque
Drain Plug/
Level Check
Plug Torque
Transmission
(Main Gearcase)
AGL Gearcase
Lubricant &
Transmission
Fluid
44 oz. (1300 ml) 10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Demand Drive Unit
(Front Gearcase)
Demand Drive
Fluid
9 oz.
(265 ml)
8-10 ft. lbs.
(11-13.6 Nm)
8-10 ft. lbs.
(11-13.6 Nm)
Electrode Gap New Plug Torque Used Plug Torque
0.7-0.8 mm 7.5 ft. lbs. (10 Nm) 7.5 ft. lbs. (10 Nm)
93
MAINTENANCE
Spark Plug
Spark Plug Removal and Replacement
1. Remove the cargo box access panel.
2. Remove the spark plug cap.
3. Using the spark plug wrench provided in the tool kit, remove the
plug by rotating it counter-clockwise.
4. Reverse the procedure for spark plug installation. Torque to
specification. See page 92.
Spark Plug Condition
Normal Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended injection oil or incorrect throttle body
adjustments.
94
MAINTENANCE
Fuses
If the engine stops or will not start, or if you experience other electrical
failures, a fuse may need replacement. Locate and correct any short
circuits that may have caused the blown fuse, then replace the fuse.
The fuse box is located under the seat. Spare fuses are provided in the
fuse box.
Main Fuse Feature Supported
20A Lights: Headlights, Taillights
20A Drive: AWD
20A Accessory: Winch Switch, 12V Power Receptacle
10A Fuel Pump
20A Electronic Engine Control, Starting
30A Engine Control
Fuse Box
95
MAINTENANCE
Fuses
Fuse Box
1. Remove the seat to access
the fuse box.
2. Squeeze the cover release
tabs inward and remove the
fuse box cover.
3. Remove the suspect fuse
from the fuse panel. If the
fuse is blown, install a new
fuse with the same amperage
rating.
4. Reinstall the fuse box cover.
5. Reinstall the seat.
Release Tabs
96
MAINTENANCE
Cooling System
Operation
The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the overflow bottle,
radiator filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the overflow bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.
Tip: Some coolant level drop on new vehicles is normal as the system is purging
itself of trapped air. Observe coolant levels and maintain as recommended
by adding coolant to the overflow bottle.
Adding or Changing Coolant
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added.
POLARIS recommends the use of POLARIS Antifreeze 60/40 premix
or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. POLARIS Antifreeze is already premixed
and ready to use. Do not dilute with water. See page 130 for the part
numbers of POLARIS products.
Tip: Always follow the manufacturer's mixing recommendations for the freeze
protection required in your area.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.
97
MAINTENANCE
Cooling System
Radiator and Cooling Fan
Always check and clean the screen and radiator fins at the intervals
outlined in the Periodic Maintenance Chart beginning on page 79. Do
not obstruct or deflect air flow through the radiator by installing
unauthorized accessories in front of the radiator or behind the cooling
fan. Interference with the radiator air flow can lead to overheating and
consequent engine damage.
NOTICE: Washing the vehicle with a high-pressure hose could damage the
radiator fins and impair the radiator's effectiveness. Using a high-
pressure system is not recommended.
Radiator Coolant Level
This procedure is required only if the cooling system has been drained
for maintenance and/or repair. But if the overflow bottle has run dry, the
level in the radiator should also be inspected.
CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.
1. Remove the front box
cover and access panel.
See page 26.
2. Slowly remove the
radiator cap.
3. View the coolant level
through the opening.
4. Use a funnel and slowly
add coolant as needed.
Tip: Use of a non-standard
pressure cap will not allow
the recovery system to
function properly. See your
POLARIS dealer for the correct replacement part.
Radiator Cap
Overflow Bottle
98
MAINTENANCE
Cooling System
Coolant Level
Always check and change the coolant at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Maintain the coolant
level between the minimum and maximum marks on the bottle (when
the fluid is cool). The coolant level in the bottle can be viewed through
the left front wheel well or in the compartment in the front box.
1. Position the vehicle on a
level surface.
2. View the coolant level in
the overflow bottle.
3. If the coolant level is
below the safe operating
range, remove the cap and
use a funnel to add
coolant through the
opening. Reinstall the cap.
Tip: If coolant must be added
often, or if the overflow bottle
runs completely dry, there
may be a leak in the system.
Have the cooling system
inspected by your POLARIS
dealer.
Radiator
Cap
Overflow
Bottle
99
MAINTENANCE
POLARIS Variable Transmission (PVT) System
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. As the owner, you have the following responsibilities for
your own safety and the safety of others:
• Always follow all recommended maintenance procedures. Always look for and
remove debris inside and around the clutch and vent system when replacing
the belt.
• See your POLARIS dealer as outlined in the owner's manual.
• This PVT system is intended for use on POLARIS products only. Do not install
it in any other product.
• Always make sure the PVT housing is securely in place during operation.
WARNING
100
MAINTENANCE
POLARIS Variable Transmission (PVT) System
Belt Replacement/Debris Removal
If a belt fails, always clean any debris from the PVT intake and outlet
duct and from the clutch and engine compartments when replacing the
belt.
WARNING! Failure to remove ALL debris when replacing the belt could result in
vehicle damage, loss of control and severe injury or death.
1. Allow hot components to cool before performing this procedure.
2. Remove the clutch cover screws and open the clutch cover. Remove
all debris wrapped in and around the PVT system.
3. Remove all debris from the entire clutch air duct passage.
4. Check for signs of damage to seals on the transmission and engine.
See your POLARIS dealer promptly for service if any seals appear
to be damaged.
Tip: Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch to
low range while operating at slower speeds to extend the life of the PVT
components (belt, cover, etc.).
101
MAINTENANCE
POLARIS Variable Transmission (PVT) System
PVT Drying
There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before
operating.
NOTICE: When washing the vehicle, always avoid spraying water directly
toward the PVT intake duct. See page 122 for recommended
washing procedures.
1. Remove the drain plug from the
bottom of the clutch box. Allow
the water to drain. Reinstall the
drain plug securely.
2. Place the transmission in PARK.
Apply the brakes. Start the
engine.
3. Apply varying throttle for 10-15
seconds to expel the moisture
and air-dry the belt and
clutches. Do not hold the
throttle wide open for more than
10 seconds.
4. Allow the engine RPM to settle
to idle speed. Apply the brakes.
Shift the transmission to the
lowest available range.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Take the vehicle to your POLARIS dealer for service as soon as
possible.
Drain Plug
102
MAINTENANCE
Air Filter
Always clean all dirt and debris away from the air box area before
servicing the air filter. Always change the air filter at the intervals
outlined in the Periodic Maintenance Chart beginning on page 79.
1. Remove the cargo box access panel.
2. Clean all dirt and debris from the air
box area BEFORE servicing the air
filter.
3. Unlatch the cover clips and carefully
remove the air box cover.
4. Loosen the air filter clamp and
remove the filter.
NOTICE: Dirt or debris in the air box could
result in severe engine damage.
Always clean all dirt and debris from
the air box before installing the filter.
5. Inspect the air box for dirt, debris, oil
or water. Compress the edges of the
air box drain to drain any water. Clean
the air box thoroughly and wipe it
well with a clean, dry cloth.
6. Reinstall the filter. Install a new filter
if needed. Do not attempt to clean the
air filter. Tighten the clamp.
7. Reinstall the air box cover and secure
the cover clips.
8. Reinstall the access panel.
Cover Clips (2)
Cover Hinges
Filter
Clamp
Air Box Drain
103
MAINTENANCE
Breather Hoses
The breather hoses run between the engine and breather box, and
between the breather box and air box.
1. Remove the hose clamps from the
engine valve cover and breather box.
Remove the hose.
2. Remove the hose clamps from the air
box and breather box. Remove the
hose.
3. Inspect the hoses for debris. Blow gently through the hoses to check
for clogging. Replace a damaged or clogged hose.
4. Check the hoses for cracks, deterioration, abrasions or leaks.
Replace as needed.
5. Reinstall the hoses and clamps.
NOTICE: Operation of the vehicle without breather hoses can cause engine
damage. Always reinstall a breather hose after removing it for
service.
Intake Pre-Filters
The engine intake pre-filter is located on the
right side of the cargo box. The PVT intake
pre-filter is located on the left side of the
cargo box.
Inspect both pre-filters before each use of
the vehicle to ensure adequate air flow. If
necessary, remove the pre-filters and clean
with soapy water. Dry with low pressure
compressed air.
NOTICE: When washing the vehicle, always
avoid spraying water directly toward
the PVT intake duct. See page 122
for recommended washing
procedures.
Breather
Hose
Engine Intake
Pre-Filter
104
MAINTENANCE
Spark Arrester
Failure to heed the following warnings while servicing the spark arrester could
result in serious injury or death.
Never run the engine in an enclosed area. Remove any combustible materials
from the area. Wear eye protection and leather work gloves. Do not stand
behind or in front of the vehicle while purging. Never go under the vehicle while
it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrester while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrester clean-out
plug from the bottom of the
muffler.
2. Place the transmission in PARK.
3. Start the engine.
4. Quickly press and release the
throttle pedal several times to
purge carbon from the system.
5. If carbon comes out of the
exhaust, cover or plug the
exhaust outlet. Wear protective
gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 4.
7. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
8. Place the transmission in PARK. Repeat steps 4 to 6 until no more
particles are expelled.
9. Stop the engine. Allow the arrester to cool.
10. Reinstall the arrester plug and remove the exhaust outlet cover or
plug.
WARNING
Exhaust Outlet
Clean-Out
Plug
105
MAINTENANCE
Throttle System
Failure to check or maintain proper operation of the throttle system can result in
an accident and lead to serious injury or death if the throttle pedal sticks during
operation.
Never start or operate this vehicle if it has a sticking or improperly operating
throttle pedal.
Immediately contact your POLARIS dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the engine
and occasionally during operation.
Throttle Freeplay
If the throttle pedal has excessive play due
to cable stretch or misadjustment, it will
cause a delay in throttle response,
especially at low engine speed. The
throttle may also not open fully. If the
throttle pedal has no freeplay, the throttle
may be hard to control, and the idle speed
may be erratic.
Check the throttle pedal freeplay at the
intervals outlined in the Periodic
Maintenance Chart beginning on page 79.
Adjust the freeplay if necessary.
Throttle Freeplay Inspection
1. Place the transmission in PARK.
2. Apply the brakes. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.5-
3 mm).
WARNING
Throttle Pedal
106
MAINTENANCE
Throttle System
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer for adjustment.
Throttle Freeplay Adjustment
1. Remove the seat. Remove
the engine access panel. See
page 28.
2. Locate the in-line throttle
cable adjuster near the
engine valve cover.
3. Slide the cable adjuster boot
off the cable adjuster.
4. Using a 10 mm open-end
wrench, loosen the
adjustment jam nut.
5. Using an 8 mm open-end
wrench, move the cable
adjuster until 1/16” to 1/8”
(1.5-3 mm) of freeplay is
achieved at the throttle pedal.
See page 105. While
adjusting, lightly flip the
throttle pedal up and down.
6. Tighten the jam nut.
7. Apply a small amount of grease to the inside of the boot and slide it
over the cable adjuster to its original position.
Throttle Cable Adjuster
Boot
Adjuster
Jam Nut
107
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes activated by the
brake pedal. See page 33.
Always check brake pedal travel and the brake fluid reservoir level
before each use of the vehicle. When applied, the brake pedal should
feel firm. Any sponginess would indicate a possible fluid leak or low
brake fluid level, which must be corrected before riding. See page 108
for brake fluid information.
If you discover any irregularities in brake system operation, including
excessive pedal travel, contact your POLARIS dealer for proper
diagnosis and repairs.
WARNING! Operating the vehicle with a spongy brake pedal can result in loss
of braking, which could cause an accident resulting in severe injury or death.
Never operate the vehicle with a spongy-feeling brake pedal.
108
MAINTENANCE
Brakes
Brake Fluid
Inspect the level of the brake fluid before each operation. If the fluid
level is low add DOT 4 brake fluid only. See page 130 for the part
numbers of POLARIS products.
WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or severe injury.
Change the brake fluid every two
years and any time the fluid
becomes contaminated, the fluid
level is below the minimum, or if
the type and brand of the fluid in
the reservoir are unknown.
Access the brake fluid reservoir
through the left front wheel well.
1. Position the vehicle on a level
surface.
2. Place the transmission in
PARK.
3. View the brake fluid level in
the reservoir. The level
should be between the
maximum and minimum
level lines.
4. If the fluid level is lower than
the lower level line, add
brake fluid to the upper line.
5. Apply the brake forcefully for
a few seconds and check for
fluid leakage around the
fittings.
Brake Fluid
Reservoir
Maximum
Minimum
Brake Fluid
Reservoir
109
MAINTENANCE
Brakes
Brake Inspection
1. Check the brake system for fluid
leaks.
2. Check the brake pedal for
excessive travel or a spongy feel.
3. Check the friction pads for wear,
damage and looseness.
4. Check brake discs for signs of
cracks, excessive corrosion,
warping or other damage. Clean
any grease using an approved
brake cleaner or alcohol.
WARNING! Do not apply WD-40 or any
petroleum product to brake discs. These
types of products are flammable and may also reduce the friction between the
brake pad and caliper.
5. Inspect the brake disc spline and pad wear surface for excessive
wear. Change pads when worn to 3/64” (1 mm).
3/64" (1mm)
110
MAINTENANCE
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 79.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is excessive freeplay or strange noises, or the steering feels
rough or “catchy,” have the steering system inspected by an autho-
rized POLARIS dealer.
Rear Spring
The rear shock absorber spring is adjusted
by rotating the adjuster either clockwise
or counter-clockwise to increase or
decrease spring tension.
Accessory springs are available through
your POLARIS dealer.
Adjuster
111
MAINTENANCE
Tires
Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8” (3 mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. Always use POLARIS-
approved size and type of tires for this vehicle when replacing tires.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8” (3 mm) or
less.
Axle and Wheel Nut Torque Specifications
Inspect the following items occasionally for tightness, and if they've
been loosened for maintenance service. Do not lubricate the stud or the
lug nut.
Lug Nut
(Aluminum
Wheels)
Front and Rear 30 ft. lbs. (41 Nm)
PLUS 1/4 TURN or
90 degrees
2-Piece Flange
Nut (Steel
Wheels)
Front and Rear 27 ft. lbs. (37 Nm)
Hub Retaining Nut Front and Rear 80 ft. lbs. (108 Nm)
WARNING
1/8" (3 mm)
112
MAINTENANCE
Tires
Wheel Removal
1. Position the vehicle on a level surface.
2. Place the transmission in PARK. Stop the engine.
3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by placing a suitable stand under the
frame.
5. Remove the wheel nuts and washers. Remove the wheel.
Wheel Installation
1. Place the transmission in PARK.
2. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation.
WARNING! Improperly installed wheels can adversely affect tire wear and
vehicle handling, which can result in serious injury or death. Always ensure that
all nuts are torqued to specification. Do not service axle nuts that have a cotter
pin installed. See your POLARIS dealer.
3. Attach the wheel nuts and washers and finger-tighten.
4. Carefully lower the vehicle to the ground.
5. Torque the wheel nuts to specification. See page 111.
113
MAINTENANCE
Lights
Headlight and taillight lenses become dirty during normal operation.
Clean all lights frequently to ensure a clear field of vision as well as vis-
ibility to other vehicles.
When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.
LED Headlamps (if equipped)
If a headlight becomes damaged or inoperable, the entire headlight
assembly must be replaced.
Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring
harness from the headlamp(s) for a few days to allow the moisture to clear
out. Do not operate the vehicle at night or in low light conditions without
properly working headlights.
Headlight Lamp Replacement
Do not service the headlamps until they've cooled sufficiently.
1. Unplug the headlamp from
the wiring harness. Be sure
to pull on the connector,
not on the wiring.
2. Turn the lamp counter-
clockwise to remove it.
3. Install the new lamp. Make
sure the tab on the lamp
locates properly in the
housing.
4. Reinstall the harness assembly into the headlight assembly.
Wiring Harness
114
MAINTENANCE
Lights
Headlight Beam Adjustment
1. Place the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall. Place the transmission in
PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Apply the brakes. Turn the ignition
switch to the LIGHTS ON position.
4. Observe the headlight aim. The most
intense part of the headlight beam
should be aimed 8" (20 cm) below the
mark placed on the wall in step 2.
Include the weight of a rider on the seat
while performing this step.
5. If adjustment is necessary, turn the
headlight adjustment screw to adjust the
beam.
6. Repeat steps 4-5 until the beam is
properly adjusted.
25 ft.
(7.6 m)
8" (20 cm)
XX
Adjustment
Screw
115
MAINTENANCE
Lights
Brake Lights
When the brake pedal is depressed, the brake light comes on. Check the
brake light before each ride.
1. Turn the ignition switch to the LIGHTS ON position.
2. Apply the brakes. The brake light should come on after about 10
mm (0.4 in.) of pedal travel. If the light doesn't come on, check the
bulb.
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result
if the machine is not thoroughly inspected. Take the vehicle to your
POLARIS dealer before starting the engine.
If it's impossible to take your vehicle to a dealer before starting it,
follow the steps outlined below.
1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter.
3. Remove the spark plug.
4. Turn the engine over several times.
5. Dry the spark plug and reinstall it, or install a new plug.
6. Attempt to start the engine. If necessary, repeat the drying
procedure.
7. Take the vehicle to your POLARIS dealer for service as soon as
possible, whether you succeed in starting it or not.
8. If water has been ingested into the PVT follow the procedure on
page 101 for drying.
116
MAINTENANCE
Battery
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be
identified by its flat covers on the top of the battery. A conventional
battery has six filler caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into a conventional battery.
WARNING
117
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
Battery Removal
1. Remove the seat. See page 28.
2. Remove the three (3) bolts securing the cup holder panel to the
frame. Lift the panel to access the battery.
3. Remove the battery hold-down strap screws and remove the strap.
4. On conventional batteries, remove the battery vent tube.
5. Disconnect the black (negative) battery cable first.
6. Disconnect the red (positive) battery cable last.
7. Lift the battery out of the vehicle. Be careful not to tip a
conventional battery sideways, which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
WARNING
Battery
Battery Hold-Down Strap
Cup Holder Panel Bolts
118
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the
battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging instructions on page 120
before installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. On conventional batteries, install the battery vent tube (sealed
batteries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.
4. Coat the terminals with dielectric grease or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Install the battery hold-down strap and tighten the screws.
8. Verify that cables are properly routed.
9. Reinstall the cup holder panel. Tighten the bolts.
10. Reinstall the seat.
119
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
See page 120.
Tip: Battery charge can be maintained by using a POLARIS Battery Tender
charger or by charging about once a month to make up for normal self-
discharge. Battery Tender can be left connected during the storage period,
and will automatically charge the battery if the voltage drops below a pre-
determined point. See page 130 for the part numbers of POLARIS
products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the
battery fluid level often. Maintain
the fluid level between the upper
and lower level marks.
Add only distilled water. Tap water
contains minerals that are harmful
to a battery.
Lower
Mark
Upper
Mark
120
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from
leaking or spilled electrolyte during charging. See page 117.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific
gravity to 1.270 or greater.
3. Reinstall the battery. See page 118. Make sure the positive terminal
is toward the front of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
Tip: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
guidelines on the next page for recharging.
121
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
122
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not
only improve its appearance but it can also
extend the life of various components.
NOTICE: Water in the PVT system could cause the
drive belt to become wet and slip in the
clutches. Always avoid spraying water
directly toward any intake pre-filters.
High water pressure may damage the
radiator fins and impair the radiator’s
effectiveness. High pressure may also
damage other vehicle components.
Certain products, including insect repellents
and chemicals, will damage plastic
surfaces. Do not allow these types of
products to contact the vehicle.
The best and safest way to clean your POLARIS
vehicle is with a garden hose and a pail of mild
soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
PVT Intake
Pre-Filter
123
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the
following items:
• Wheel bearings
• Radiator
• Transmission seals
•Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
• Air intake components
If warning and safety labels are damaged, contact your POLARIS dealer
for free replacement.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
124
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion,
preserve wheel life and ensure a “like new” appearance for many years.
Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are
more susceptible to corrosion if not properly cleaned. Clean chrome wheels
more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each
polished chrome wheel. Choose a product suitable for chrome
finishes. Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as
outlined above.
125
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 122.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the
recommended amount. Carbon Clean removes water from fuel
systems, stabilizes fuel and removes carbon deposits from pistons,
rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel delivery system.
Oil and Filter
Change the oil and filter. See page 88.
Air Filter / Air Box
Inspect and clean or replace the pre-filter and air filter. Clean the air
box. See pages 102-103.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 79.
• Demand drive fluid (front gearcase)
• Rear gearcase fluid (if equipped)
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
126
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 79.
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean. Follow the
instructions on the container. Start the engine. Allow it to idle for
several minutes so the Carbon Clean reaches the injectors. Stop the
engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To
access the plug holes, use a section of clear 1/4” hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
Do this carefully! If you miss the plug holes, oil will drain from the
spark plug cavities into the hole at the front of the cylinder head,
and appear to be an oil leak.
3. Reinstall the spark plug. Torque to specification. See page 93.
4. Apply dielectric grease to the inside of each spark plug cap. Do not
reinstall the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a
protective film of fresh oil.
6. If POLARIS fuel system additive is not used, fuel tank, fuel lines,
and injectors should be completely drained of gasoline.
7. Reinstall the spark plug cap to the spark plug.
Battery Maintenance
See pages 119-121 for storage and charging procedures.
Storage Area/Covers
Be sure the storage area is well ventilated. Cover the vehicle with a
genuine POLARIS cover. Do not use plastic or coated materials. They
do not allow enough ventilation to prevent condensation, and may
promote corrosion and oxidation.
127
MAINTENANCE
Cleaning and Storage
Removal from Storage
1. Check the battery electrolyte level and charge the battery if
necessary. Install it in the vehicle. Make sure the battery vent hose is
routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 48. Tightness of the bolts, nuts and other fasteners should
be checked by an authorized POLARIS dealer.
5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 79.
WARNING! Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness or death. Never run an engine in an enclosed area.
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Place the transmission in PARK. Stop the engine.
2. Remove the key to prevent loss during transporting.
3. Secure the fuel cap and seat. Ensure that the seat is attached
correctly and is not loose.
WARNING! Cargo and other loose vehicle parts may fly off while transporting
this vehicle. Secure or remove all cargo, and inspect the unit for loose parts prior
to transport.
4. Always tie the frame of the POLARIS vehicle to the transporting
unit securely with suitable straps or rope. Do not attach tie straps to
the front control arm bolt pockets.
128
SPECIFICATIONS
SPORTSMAN ACE
Gross Vehicle Weight 1455 lbs. (660 kg)
Dry Weight 835 lbs. (379 kg)
Test GVW - Rollover Protection
System (ROPS)
1505 lbs. (682.7 kg) per OSHA 29 CFR 1928.53
Front Rack/Box Capacity 120 lbs. (54 kg)
Rear Rack/Box Capacity 240 lbs. (108 kg)
Maximum Weight Capacity
(Payload)
575 lbs. (260 kg) (operator/cargo/accessories/
trailer tongue weight)
Receiver Hitch Tongue Capacity 150 lbs. (68 kg)
Receiver Hitch Towing Capacity 1500 lbs. (680 kg
Fuel Capacity 5.25 gal. (19.9 l)
Engine Oil Capacity 1.75 qts. (1.65 l)
Coolant System Capacity 86 oz. (2.5 l) excluding coolant bottle
Coolant Bottle Capacity 8 oz. (237 ml)
Demand Drive Fluid Capacity 9 oz. (265 ml)
Transmission Oil Capacity 44 oz. (1300 ml)
Overall Length/Width/Height 90/48/68 in. (228.6/122/173 cm)
Wheelbase 61.5 in. (156.2 cm)
Ground Clearance 10.25 in. (26 cm)
Engine Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement 325 cc
Bore x Stroke 78mm x 68mm
Alternator Output 450 W @ 7000 RPM
Compression Ratio 11.5:1
Starting System Electric
Fuel System Electronic fuel injection
Throttle Body Size 36 mm
Ignition System Digital CDI
Ignition Timing 32° +/- 2° @ 5000 RPM
Spark Plug / Gap RG6YC / .035 in. (0.7-0.8 mm)
Front Suspension MacPherson strut with 8.2 in. (20.8 cm) travel
Rear Suspension Dual A-arm, anti-sway bar with 9.5 in. (24.1 cm)
travel
129
SPECIFICATIONS
Clutching
Please see your dealer for clutching specifications.
SPORTSMAN ACE
Lubrication System Wet Sump
Engine Oil PS-4 5W-50
Driving System Type Automatic POLARIS Variable Transmission
Shift Type Side Lever (H/L/N/R/P)
Gear Reduction - Low 28.84:1
Gear Reduction - Reverse 25.83:1
Gear Reduction - High 9.65:1
Drive Ratio - Front 2.989:1
Tire Size - Front 25x8-12
Tire Size - Rear 25x10-12
Tire Pressure Front: 7 psi (48 KPa)
Rear: 7 psi (48 KPa)
Brakes, Park Park in Transmission
Brakes, Front/Rear Foot Activated, 4-wheel hydraulic disc
Headlights 2 single beam, 55W halogen
Taillights 2 single beam, 6W
Brake Lights 2 single beam, 27W
Instrument Cluster LCD
Auxiliary DC Outlet 12V
130
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz./355 ml Aerosol)
2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(gal./3.8 l)
2870465 Pump for Gallon (3.8 l) Jug
2877922 Demand Drive Fluid (qt./.95 l)
2877923 Demand Drive Fluid (gal./3.8 l)
Coolant
2871534 POLARIS Antifreeze 60/40 Premix (qt./.95 l)
2871323 POLARIS Antifreeze 60/40 Premix (gal./3.8 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
2871460 Premium Starter Grease
2871515 U-Joint Grease (3 oz./89 ml cartridge)
2871551 U-Joint Grease (14 oz./414 ml cartridge)
2871329 Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326 Carbon Clean
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956 Loctite™ 565 Thread Sealant
2859044 POLARIS Battery Tender™ Charger
131
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range during loading.
Starting out going up a
steep incline
Use low range. See warnings on page 58.
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle rollover.
Climbing over large
objects from a stopped
position
Shift the transmission to low range and carefully use fast,
brief, aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle rollover.
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT (see page 101). Prevent water from
entering the PVT intake duct (see page 103). Inspect
clutch seals for damage if repeated leaking occurs.
Clutch malfunction See your POLARIS dealer.
Poor engine performance Check for fouled plug or foreign material in gas tank or
fuel lines. See your POLARIS dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 46.
132
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Loose electronic control box connections Inspect, clean, reinstall connectors
Possible Cause Solution
Out of fuel Refuel
Clogged fuel filter See your POLARIS dealer
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug Inspect plug and replace if necessary
No spark to spark plug Inspect plug and replace if necessary
Water or fuel in crankcase Immediately see your POLARIS dealer
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your POLARIS dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark plug
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your POLARIS dealer
Incorrect ignition timing See your POLARIS dealer
Mechanical failure See your POLARIS dealer
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
133
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your POLARIS dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Possible Cause Solution
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug wires See your POLARIS dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Low fuel pressure See your POLARIS dealer
Other mechanical failure See your POLARIS dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter See your POLARIS dealer
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
134
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Refuel
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug wires See your POLARIS dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Other mechanical failure See your POLARIS dealer
Overheated engine Clean radiator screen and core, clean
engine exterior, see your POLARIS
dealer
135
WARRANTY
LIMITED WARRANTY
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX
MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against
defects in material or workmanship. POLARIS further warrants that the spark arrestor in
this product will meet the efficiency requirements of USFS standard 5100-1C for at least
1000 hours when subjected to normal use and when maintenance and installation are in
accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective parts
and begins on the date of purchase by the original retail purchaser. This warranty is
transferable to another owner during the warranty period through a POLARIS dealer,
but any such transfer will not extend the original term of the warranty. The duration of
this warranty may vary by international region based upon local laws and regulations.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days of purchase. Upon receipt of this
registration, POLARIS will record the registration for warranty. No verification of
registration will be sent to the purchaser as the copy of the Warranty Registration Form
will be your proof of warranty coverage. If you have not signed the original registration
and received the customer copy, please contact your dealer immediately. NO
WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS
REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is
very important in ensuring trouble-free operation. Purchasing a machine in the crate or
without proper dealer set-up will void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
This POLARIS limited warranty excludes any failures that are not caused by a defect in
material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF
DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental
damage, normal wear and tear, abuse or improper handling. This warranty also does not
cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained, or used for purposes other than for which it was
designed.
This warranty excludes damages or failures resulting from: improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external stress,
heat, cold or contamination; operator error or abuse; improper component alignment,
tension, adjustment or altitude compensation; snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket or unapproved components, accessories, or attachments; unauthorized
repairs; or repairs made after the warranty period expires or by an unauthorized repair
center.
136
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty excludes damages or failures caused by abuse, accident, fire, or any other
cause other than a defect in materials or workmanship and provides no coverage for
consumable components, general wear items, or any parts exposed to friction surfaces,
stresses, environmental conditions and/or contamination for which they were not
designed or not intended, including but not limited to the following items:
Lubricants and Fluids
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is
not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage,
transportation costs, hotels, meals, shipping or handling fees, product pick-up or
delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or
personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,
AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN
THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON
FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY
TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR
IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR
OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL
SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS
ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL
EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO
NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION
OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY
TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components and fluids
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps • Spark plugs
• Filter • Sealants
• Lubricants • Coolants
• Bushings • Bearings
137
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS Servicing
Dealer. When requesting warranty service you must present your copy of the Warranty
Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use
your original selling dealer; however, you may use any POLARIS Servicing Dealer to
perform warranty service.
In the country where your product was purchased:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If
you move or are traveling within the country where your product was purchased,
Warranty and Service Bulletin repairs may be requested from any authorized POLARIS
dealer that sells the same line as your product.
Outside the country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased,
you should take your product to an authorized POLARIS dealer. You must show the
dealer photo identification from the country of the selling dealer’s authorized location as
proof of residence. Upon residence verification, the servicing dealer will be authorized
to perform the warranty repair.
If you move:
If you move to another country, be sure to contact POLARIS Customer Assistance and
the customs department of the destination country before you move. Product
importation rules vary considerably from country to country. You may be required to
present documentation of your move to POLARIS in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS in order to
register your product in your new country. You should warranty register your product at
a local POLARIS dealer in your new country immediately after you move to continue
your warranty coverage and to ensure that you receive information and notices regarding
your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside of
the country in which the product was originally purchased, all warranty coverage will be
denied. You must nonetheless register your product under your name and address with a
local POLARIS dealer in your country to ensure that you receive safety information and
notices regarding your product.
138
WARRANTY
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS
SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED
LOCATION. This policy does not apply to products that have received authorization for
export from POLARIS. Dealers may not give authorization for export. You should
consult an authorized dealer to determine this product’s warranty or service coverage if
you have any questions. This policy does not apply to products registered to government
officials or military personnel on assignment outside the country of the selling dealer’s
authorized location. This policy does not apply to Safety Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and you have
not followed the procedure set above, your product will no longer be eligible for
warranty or service bulletin coverage of any kind, other than safety bulletins. Products
registered to Government officials or military personnel on assignment outside of the
country where the product was purchased will continue to be covered by the Limited
Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance, they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state or in different countries. If any of the above terms are void
because of federal, state, local law, all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
139
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first
purchased, this emissions-certified vehicle is designed, built and equipped so it
conforms with applicable U.S. Environmental Protection Agency emission regulations.
POLARIS warrants that the vehicle is free from defects in materials and workmanship
that would cause it to fail to meet these regulations.
The warranty period for off-road vehicles 100cc or greater emissions-certified vehicles
starts on the date of purchase by original retail purchaser and continues for a period of
500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30
calendar months from the date of purchase, whichever comes first. The warranty period
for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by
original retail purchaser and continues for a period of 250 hours of engine operation,
2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of
purchase, whichever comes first. This EPA emissions warranty period is extended for at
least as long as the standard factory warranty that Polaris provides on the vehicle as a
whole. The EPA emissions warranty period does not further extend if you purchase
additional warranty coverage in the form of a service contract or other paid warranty
extension, but emission-related parts may be covered subject to the terms of any such
paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the
vehicle’s regulated emissions, and it covers components of systems whose only purpose
is to control emissions. Repairing or replacing other components not covered by this
warranty is the responsibility of the vehicle owner. This emissions limited warranty does
not cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
The following parts are also considered emission-related components for exhaust
emissions:
• Air-induction system • Ignition system
• Fuel system • Exhaust gas recirculation systems
• Aftertreatment devices • Sensors
• Crankcase ventilation valves • Electronic control units
140
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The following parts are considered emission-related components for evaporative
emissions:
*As related to the evaporative emission control system.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of POLARIS, repair or replacement of any defective materials, components or
products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED
WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR
OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL
PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply
if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover damage due to accidents, abuse or
improper handling, maintenance or use. This limited warranty also does not cover any
engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or
defects caused by fire, explosions or other similar causes beyond the control of
POLARIS.
• Fuel Tank • Vacuum Control Diaphragms*
• Fuel Cap • Control Cables*
• Fuel Line • Control Linkages*
• Fuel Line Fittings • Purge Valves
• Clamps* • Vapor Hoses
• Pressure Relief Valves* • Liquid/Vapor Separator
• Control Valves* • Carbon Canister
• Control Solenoids* • Canister Mounting Brackets
• Electronic Controls* • Carburetor Purge Port Connector
141
WARRANTY
U.S.A. EPA Emissions Limited Warranty
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. POLARIS may deny warranty claims for failures that have been caused
by the owner’s or operator’s improper maintenance or use, by accidents for which
POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission
control devices or systems on your vehicle. POLARIS recommends that you contact an
authorized POLARIS dealer to perform any service that may be necessary for your
vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a
potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering
with emission controls is prohibited by federal law.
California Residents
Certain POLARIS off-road vehicles are available in 49-state and 50-state versions. Only
the 50-state models are certified for sale in California. The 50-state models available for
sale in California are identified by the letter “C” in the model name (e.g.,
R13UH88A_C). The POLARIS 50-state models are designed and built with features
such as a reduced cargo box capacity. Any modifications to these features may be a
violation of the applicable California regulations and may void this limited emissions
warranty offered by the manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please
contact POLARIS Customer Assistance.
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
142
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
143
INDEX
A
Access Panels . . . . . . . . . . . . . . . . . . 25
Accessory Outlet. . . . . . . . . . . . . . . . 31
Adding Coolant. . . . . . . . . . . . . . . . . 96
Adjustment
Seat. . . . . . . . . . . . . . . . . . . . . . . . 28
Steering Wheel. . . . . . . . . . . . . . . 26
Adjustment, Headlight Beam . . . . . 114
Adjustment, Throttle Freeplay . . . . 106
Age Restrictions . . . . . . . . . . . . . . . . 14
Air Filter . . . . . . . . . . . . . . . . . . . . . 102
Air Filter Cleaning . . . . . . . . . . . . . 102
All Wheel Drive Switch . . . . . . . . . . 31
All Wheel Drive System. . . . . . . . . . 35
Arrester Cleaning . . . . . . . . . . . . . . 104
Auxiliary Outlet . . . . . . . . . . . . . . . . 31
AWD Switch. . . . . . . . . . . . . . . . 31, 35
AWD System . . . . . . . . . . . . . . . . . . 35
Axle Nut Torque. . . . . . . . . . . . . . . 111
B
Battery . . . . . . . . . . . . . . . . . . 116-121
Charging. . . . . . . . . . . . . . . . . . . 120
Charging (Sealed Battery) . 120-121
Battery Fluid Replenishment . . . . . 119
Battery Installation . . . . . . . . . . . . . 118
Battery Removal. . . . . . . . . . . . . . . 117
Battery Storage . . . . . . . . . . . . . . . . 119
Before Riding . . . . . . . . . . . . . . . . . . 48
Belt Burning . . . . . . . . . . . . . . . . . . 131
Belt Life . . . . . . . . . . . . . . . . . . . . . . 65
Belt Replacement . . . . . . . . . . . . . . 100
Belt Wear . . . . . . . . . . . . . . . . . . . . 131
Belt, Seat. . . . . . . . . . . . . . . . . . . . . . 29
Boots. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Box Cover, Front . . . . . . . . . . . . . . . 26
Brake Fluid . . . . . . . . . . . . . . . . . . . 108
Brake Inspection. . . . . . . . . . . . . . . 109
Brake Lights . . . . . . . . . . . . . . . . . . 115
Brake Pedal. . . . . . . . . . . . . . . . . . . . 33
Brake System Break-in. . . . . . . . . . . 47
Brakes . . . . . . . . . . . . . . . . . . . 107-109
Braking . . . . . . . . . . . . . . . . . . . . . . . 53
Break-In Period. . . . . . . . . . . . . . 46-47
Breather Hoses . . . . . . . . . . . . . . . . 103
Bumper Removal . . . . . . . . . . . . . . . 25
Burning Belts . . . . . . . . . . . . . . . . . 131
C
Cab Frame, ROPS. . . . . . . . . . . . . . . 34
Cab Nets . . . . . . . . . . . . . . . . . . . . . . 27
Cap, Fuel. . . . . . . . . . . . . . . . . . . . . . 28
Cargo. . . . . . . . . . . . . . . . . . . . . . 64-65
Changing Coolant. . . . . . . . . . . . . . . 96
Changing Gears . . . . . . . . . . . . . . . . 32
Chart, Periodic Maintenance . . . 79-83
Check Engine Indicator . . . . . . . . . . 43
Chrome Wheel Care . . . . . . . . . . . . 124
Cleaning and Storage . . . . . . . 122-127
Cleaning the Air Filter . . . . . . . . . . 102
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching. . . . . . . . . . . . . . . . . . . . . 129
Component Locations. . . . . . . . . . . . 24
Condition, Spark Plugs. . . . . . . . . . . 93
Coolant Level . . . . . . . . . . . . . . . . . . 98
Coolant Level, Radiator . . . . . . . . . . 97
Coolant, Adding or Changing. . . . . . 96
Cooling Fan . . . . . . . . . . . . . . . . . . . 97
Cooling System. . . . . . . . . . . . . . 97-98
Cooling System Operation . . . . . . . . 96
Corrosion Removal, Chrome . . . . . 124
Cover for Storage . . . . . . . . . . . . . . 126
Crankcase Emission Control System 78
D
Demand Drive Fluid . . . . . . . . . . . . . 90
Diagnostic Codes . . . . . . . . . . . . . . . 45
Diagnostic Display Code Definitions 45
Display Units, Standard/Metric . . . . 40
Drive Belt Wear . . . . . . . . . . . . . . . 131
Drivetrain Break-In. . . . . . . . . . . . . . 47
Driving Downhill . . . . . . . . . . . . . . . 60
Driving in Reverse . . . . . . . . . . . . . . 63
Driving on a Sidehill. . . . . . . . . . . . . 59
Driving on Slippery Surfaces . . . . . . 57
Driving Over Obstacles . . . . . . . . . . 62
Driving Procedures . . . . . . . . . . . 54-55
Driving Through Water . . . . . . . . . . 61
Driving Uphill. . . . . . . . . . . . . . . . . . 58
Driving, After Driving in Water. . . 101
Drying the Transmission. . . . . . . . . 101
144
INDEX
E
Electromagnetic Interference. . . . . . 78
Emission Control, Crankcase. . . . . . 78
Emission Control, Exhaust . . . . . . . 78
Emission Control, Noise . . . . . . . . . 78
Emissions Limited Warranty. . 139-141
Engaging AWD . . . . . . . . . . . . . . . . 35
Engine Break-In. . . . . . . . . . . . . . . . 47
Engine Fogging . . . . . . . . . . . . . . . 126
Engine Idle Speed . . . . . . . . . . . . . 106
Engine Intake Pre-Filter. . . . . . . . . 103
Engine Oil . . . . . . . . . . . . . . . . . . 86-89
Engine Starting . . . . . . . . . . . . . . . . 52
Engine Stopping. . . . . . . . . . . . . . . . 53
Equipment Modifications . . . . . . . . 23
Error Codes, Engine. . . . . . . . . . . . . 43
Etiquette, Trail Riding. . . . . . . . . . . 49
Exhaust Emission Control System. . 78
Exhaust Pipe Cleaning. . . . . . . . . . 104
Eye Protection . . . . . . . . . . . . . . . . . . 9
F
Fan, Cooling . . . . . . . . . . . . . . . . . . 97
Filling the Battery . . . . . . . . . . . . . 119
Filter Care During Storage. . . . . . . 125
Filter Cleaning, Air . . . . . . . . . . . . 102
Filter, Air . . . . . . . . . . . . . . . . . . . . 102
Fluid
Demand Drive. . . . . . . . . . . . . . . 90
Front Gearcase . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . 91
Transmission. . . . . . . . . . . . . . . . 91
Fluid Change
Demand Drive. . . . . . . . . . . . . . . 90
Front Gearcase . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . 91
Transmission. . . . . . . . . . . . . . . . 91
Fluid Check
Coolant Bottle. . . . . . . . . . . . . . . 98
Demand Drive. . . . . . . . . . . . . . . 90
Front Gearcase . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . 91
Radiator Coolant. . . . . . . . . . . . . 97
Transmission. . . . . . . . . . . . . . . . 91
F
Fluid Levels During Storage . . . . . . 125
Fluid Recommendations, Gearcase . . 92
Fluid, Battery. . . . . . . . . . . . . . . . . . 119
Fluid, Brake . . . . . . . . . . . . . . . . . . . 108
Fogging the Engine . . . . . . . . . . . . . 126
Fouled Plugs . . . . . . . . . . . . . . . . . . . 93
Freeplay Adjustment, Throttle. . . . . 106
Freeplay, Steering Wheel . . . . . . . . 110
Freeplay, Throttle . . . . . . . . . . . . . . 105
Front Box Cover . . . . . . . . . . . . . . . . 26
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . 28
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 22
Fuel Stabilizer . . . . . . . . . . . . . . . . . 125
Fuel Tank Filler Cap . . . . . . . . . . . . . 28
Fuse Box . . . . . . . . . . . . . . . . . . . . . . 95
Fuses . . . . . . . . . . . . . . . . . . . . . . 94-95
G
Gap, Spark Plug. . . . . . . . . . . . . . . . . 92
Gasoline Handling. . . . . . . . . . . . . . . 22
Gear Selector . . . . . . . . . . . . . . . . . . . 32
Gearcase Capacities. . . . . . . . . . . . . . 92
Gearcase Oil
Demand Drive. . . . . . . . . . . . . . . . 90
Front . . . . . . . . . . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . . 91
Gearcase Specifications. . . . . . . . . . . 92
Gearcases . . . . . . . . . . . . . . . . . . 90-92
Demand Drive. . . . . . . . . . . . . . . . 90
Front Gearcase . . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . . 91
Specification Chart . . . . . . . . . . . . 92
Transmission. . . . . . . . . . . . . . . . . 91
Gears, shifting . . . . . . . . . . . . . . . . . . 32
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
H
Hauling a Load . . . . . . . . . . . . . . 64-65
Hauling Cargo . . . . . . . . . . . . . . . 64-65
Headlight Beam Adjustment . . . . . . 114
Headlight Lamp Replacement. . . . . 113
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hitch . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hitch Weight . . . . . . . . . . . . . . . . . . . 66
145
INDEX
I
Idle Speed . . . . . . . . . . . . . . . . . . . . 106
Ignition Switch . . . . . . . . . . . . . . . . . 31
Indicator Lamps . . . . . . . . . . . . . . . . 37
Inspection, Axle Nuts . . . . . . . . . . . 111
Inspection, Brakes. . . . . . . . . . . . . . 109
Inspection, Pre-Ride . . . . . . . . . . . . . 48
Inspection, Steering Wheel. . . . . . . 110
Inspection, Throttle Freeplay . . . . . 105
Inspection, Wheel Nuts. . . . . . . . . . 111
Installation, Battery. . . . . . . . . . . . . 118
Installation, Wheels . . . . . . . . . . . . 112
Instrument Cluster. . . . . . . . . . . . 36-45
Interference, Electromagnetic. . . . . . 78
K
Key, Periodic Maintenance Chart. . . 80
L
Light Switch . . . . . . . . . . . . . . . . . . . 31
Lights . . . . . . . . . . . . . . . . . . . 113-115
Beam Adjustment. . . . . . . . . . . . 114
Brake Lights. . . . . . . . . . . . . . . . 115
Headlight Lamp Replacement . . 113
Loads, Towing . . . . . . . . . . . . . . . . . 66
Lubricant Part Numbers . . . . . . . . . 130
Lubrication for Storage. . . . . . . . . . 126
Lubrication Recommendations. . 84-85
M
Maintenance Log . . . . . . . . . . . . . . 142
Maintenance, Periodic . . . . . . . . 79-83
Metric Display . . . . . . . . . . . . . . . . . 40
Mode Button. . . . . . . . . . . . . . . . . . . 36
Muffler Cleaning. . . . . . . . . . . . . . . 104
N
Nets, Cab. . . . . . . . . . . . . . . . . . . . . . 27
New Operator Procedures. . . . . . 54-55
Noise Emission Control System. . . . 78
O
Obstacles. . . . . . . . . . . . . . . . . . . . . . 62
Oil
Demand Drive . . . . . . . . . . . . . . . 90
Engine . . . . . . . . . . . . . . . . . . 86-89
Front Gearcase . . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . . 91
Transmission . . . . . . . . . . . . . . . . 91
Oil and Filter Care During Storage. 125
Oil Change
Demand Drive . . . . . . . . . . . . . . . 90
Engine . . . . . . . . . . . . . . . . . . . . . 89
Engine Oil . . . . . . . . . . . . . . . . . . 88
Front Gearcase . . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . . 91
Transmission . . . . . . . . . . . . . . . . 91
Oil Check
Demand Drive . . . . . . . . . . . . . . . 90
Engine Oil . . . . . . . . . . . . . . . . . . 87
Front Gearcase . . . . . . . . . . . . . . . 90
Main Gearcase . . . . . . . . . . . . . . . 91
Transmission . . . . . . . . . . . . . . . . 91
Oil Recommendations . . . . . . . . . . . 86
Operation on Public Lands . . . . . . . . 78
Operation, Cooling System. . . . . . . . 96
Operation, Transmission. . . . . . 99-101
Operator Restrictions . . . . . . . . . . . . 14
P
Parking on an Incline . . . . . . . . . . . . 63
Parking the Vehicle. . . . . . . . . . . . . . 53
Periodic Maintenance Chart . . . . 79-83
Plug Condition . . . . . . . . . . . . . . . . . 93
Plug Gap . . . . . . . . . . . . . . . . . . . . . . 92
Plug Torque . . . . . . . . . . . . . . . . . . . 92
Plug, Accessory . . . . . . . . . . . . . . . . 31
Plug, Spark . . . . . . . . . . . . . . . . . 92-93
Plugs, Fouled . . . . . . . . . . . . . . . . . . 93
Polaris Products . . . . . . . . . . . . . . . 130
Polishing the Vehicle . . . . . . . . . . . 123
Pre-Filters, Intake . . . . . . . . . . . . . . 103
Pre-Ride Inspection . . . . . . . . . . . . . 48
Public Lands . . . . . . . . . . . . . . . . . . . 78
146
INDEX
P
PVT Break-In. . . . . . . . . . . . . . . . . . 47
PVT Drying . . . . . . . . . . . . . . . . . . 101
PVT Intake Pre-Filter . . . . . . . . . . 103
PVT System Operation . . . . . . . 99-101
PVT, Cleaning Debris . . . . . . . . . . 100
R
Radiator . . . . . . . . . . . . . . . . . . . . . . 97
Radiator Access . . . . . . . . . . . . . . . . 25
Radiator Coolant Level . . . . . . . . . . 97
Receiver Hitch . . . . . . . . . . . . . . . . . 25
Refueling Safety . . . . . . . . . . . . . . . 22
Removal, Battery. . . . . . . . . . . . . . 117
Removal, Seat . . . . . . . . . . . . . . . . . 28
Removal, Wheels. . . . . . . . . . . . . . 112
Removing the Vehicle from Storage 127
Restrictions, Age . . . . . . . . . . . . . . . 14
Reverse . . . . . . . . . . . . . . . . . . . . . . 63
Rider Information Center. . . . . . . 38-43
Riding Area . . . . . . . . . . . . . . . . . . . 49
Riding Gear . . . . . . . . . . . . . . . . . . . 8-9
Rollover Protective Structure . . . . . 34
ROPS Cab Frame. . . . . . . . . . . . . . . 34
RPM, Idle, Throttle Body . . . . . . . 106
S
Safe Operation Practices . . . . . . . 50-51
Safety Labels . . . . . . . . . . . . . . . . 10-13
Safety Symbols . . . . . . . . . . . . . . . . . 4
Safety Training . . . . . . . . . . . . . . . . . 7
Safety Training, ROHVA . . . . . 50, 54
Safety Warnings. . . . . . . . . . . . . . 14-23
Safety, Winch Maintenance. . . . . . . 77
Seat Adjustment. . . . . . . . . . . . . . . . 28
Seat Belt. . . . . . . . . . . . . . . . . . . . . . 29
Seat Removal. . . . . . . . . . . . . . . . . . 28
Selector, Gear . . . . . . . . . . . . . . . . . 32
Service Panels . . . . . . . . . . . . . . . . . 25
Severe Use Definition . . . . . . . . . . . 79
Shifting Gears . . . . . . . . . . . . . . . . . 32
Shock Loading the Winch . . . . . . . . 76
Signal Words . . . . . . . . . . . . . . . . . . . 4
S
Spark Arrester, Cleaning . . . . . . . . . 104
Spark Plug . . . . . . . . . . . . . . . . . . 92-93
Spark Plug Condition. . . . . . . . . . . . . 93
Spark Plug Gap . . . . . . . . . . . . . . . . . 92
Spark Plug Removal . . . . . . . . . . . . . 93
Spark Plug Torque. . . . . . . . . . . . . . . 92
Spark Plugs, Fouled. . . . . . . . . . . . . . 93
Specifications. . . . . . . . . . . . . . . . . . 128
Specifications, Gearcase . . . . . . . . . . 92
Speed, Idle. . . . . . . . . . . . . . . . . . . . 106
Speed, Towing. . . . . . . . . . . . . . . . . . 66
Speedometer . . . . . . . . . . . . . . . . . . . 36
Spring Adjustment, Rear Shock . . . 110
Stabilizing the Fuel . . . . . . . . . . . . . 125
Starting the Engine . . . . . . . . . . . . . . 52
Steering Wheel Adjustment. . . . . . . . 26
Steering Wheel Inspection. . . . . . . . 110
Stopping the Engine. . . . . . . . . . . . . . 53
Storage. . . . . . . . . . . . . . . . . . . 122-127
Storage and Inspection. . . . . . . . . . . 126
Storage and Lubrication. . . . . . . . . . 126
Storage Area . . . . . . . . . . . . . . . . . . 126
Storage, Battery . . . . . . . . . . . . . . . . 119
Storage, Covers . . . . . . . . . . . . . . . . 126
Storage, Fluid Levels. . . . . . . . . . . . 125
Storage, Oil and Filter . . . . . . . . . . . 125
Storage, Removal. . . . . . . . . . . . . . . 127
Switches
AWD Switch. . . . . . . . . . . . . . 31, 35
Ignition Switch . . . . . . . . . . . . . . . 31
Light Switch . . . . . . . . . . . . . . . . . 31
Mode Button. . . . . . . . . . . . . . . . . 36
T
Tachometer . . . . . . . . . . . . . . . . . . . . 41
Throttle Freeplay . . . . . . . . . . . . . . . 105
Throttle Freeplay Adjustment . . . . . 106
Throttle Freeplay Inspection . . . . . . 105
Throttle Pedal . . . . . . . . . . . . . . . . . . 33
Throttle System . . . . . . . . . . . . . . . . 105
Tire Tread Depth . . . . . . . . . . . . . . . 111
Tires. . . . . . . . . . . . . . . . . . . . . 111-112
147
INDEX
T
Torque, Axle Nuts. . . . . . . . . . . . . . 111
Torque, Spark Plug . . . . . . . . . . . . . . 92
Torque, Wheel Nut . . . . . . . . . . . . . 111
Towing Loads. . . . . . . . . . . . . . . . . . 66
Towing Speed . . . . . . . . . . . . . . . . . . 66
Trail Etiquette . . . . . . . . . . . . . . . . . . 49
Trailer Hitch . . . . . . . . . . . . . . . . . . . 25
Training. . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil. . . . . . . . . . . . . . . . 91
Transmission Operation . . . . . . 99-101
Transmission, Drying . . . . . . . . . . . 101
Transporting the Vehicle . . . . . . . . 127
Tread Depth, Tire . . . . . . . . . . . . . . 111
Tread Lightly . . . . . . . . . . . . . . . . . . 49
Turning the Vehicle . . . . . . . . . . . . . 56
V
Vehicle Identification Numbers . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . 115
Vehicle Transport . . . . . . . . . . . . . . 127
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . 122-123
Water, Immersion of Vehicle . . . . . 115
Wear, Drive Belt. . . . . . . . . . . . . . . 131
Weight, Hitch . . . . . . . . . . . . . . . . . . 66
Wheel Installation. . . . . . . . . . . . . . 112
Wheel Nut Torque . . . . . . . . . . . . . 111
Wheel Removal . . . . . . . . . . . . . . . 112
Winch Cable Care. . . . . . . . . . . . . . . 75
Winch Maintenance/Service Safety . 77
Winch Operation. . . . . . . . . . . . . 70-74
Winch Safety Precautions. . . . . . 67-69
Winch Shock Loading . . . . . . . . . . . 76
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER Operate:
• Without first viewing safety video and taking a ROHVA training course at
www.rohva.org.
• If you are under age 16 and without a valid driver’s license.
• On excessively steep hills.
• On public roads (unless designated for off-road use).
ALWAYS:
• Secure cab nets or doors and keep hands and feet inside vehicle at all times.
• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
• Wear your seat belt. Vehicle rollover can cause severe injury or death.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-Polaris approved accessories - they may seriously affect stability.
For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polaris.com
Polaris Sales Inc.
2100 Hwy. 55
Medina, MN 55340
Phone 1-888-704-5290
Part No. 9924083 Rev 01
Printed in USA
RIDER MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR.
RIDER MUST WEAR SEAT BELT.
NEVER USE ON PUBLIC ROADS.
NEVER USE WITH DRUGS OR ALCOHOL.
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
